Tetsuya Watanabe Sharps Technology of Glass Glass Thin Film Silicon PV Module

4th Saudi Solar Energy Forum, May 8th and 9th , Riyadh Saudi Arabia
Sharps Technology of Glass-glass Thin-Film Silicon PV Module

Tetsuya WATANABE Solar Systems Group, Sharp Corporation
4thSSEF,May8and9,Riyadh 1
StrictlyConfidential
Contents
1. Brief Introduction of Sharp Solar Business 2. Technology of Glass-glass Thin-Film Silicon PV Module 1) Advantage of Thin-Film Si PV for Power Generation 2) Sharp Thin Film - Glass-glass 3. Mega-Solar Power Generation Plants 1) Special Features of Sharp Systems Solutions 2) Examples of Mega-Solar Plants using Sharp Modules
4thSSEF,May8and9,Riyadh
1. Brief Introduction of Sharp Solar Business
Solar Business Our History

Crystalline 53 CrystallineSilicon SiliconTechnology: Technology: 53years yearsof ofexperience experience
1959
Development of PV cells 50th anniversary
1963
1967
1970
Start producing Space-use PV cells
1981
Start business in Katsuragi Plant
2008
2011
Development Mass production of Space-use PV cells of PV cells
IEEE milestone recognition
1963 Sakai factory starts operation

* As of April 2010 Source:JAPAN COAST GUARD More than 2,500 installations in Japan* sourceJAXA Equipped with more than 160 satellites*
2012
Thin -Film Silicon 32 Thin-Film SiliconTechnology: Technology: 32years yearsof ofexperience experience
R&D of amorphous thin-film starts 1998 Mass production of amorphous Thin-Film module starts 2005 Mass production of tandem type Thin-Film module starts
1980
1998
2005
2008
2011
2008 Mass production of large size tandem Thin-Film module starts
For higher For higher efficiency efficiency
For more For more cost effectiveness cost effectiveness
Super see-through ThinFilm PV module (Japan)
Mega Solar Power Generation installation (Thailand) 4
Solar Business Wide Range Products

Commercialized Commercialized Products Products Mono-crystalline System System // BOS BOS
Inverter
Crystalline
Cell
Module
Silicon
Ingot
Polycrystalline Cell
Module See-through type
PV Cell
Thin-Film (Amorphous, Micro-crystal)

Module See-through type Flexible type
Solar street light
Mono-crystalline (GaAs) Compounds

Compound semiconductor cell
Poly-crystalline (CdS,CdTe,CulnGaSe2, etc.) Dye sensitization
Off grid system
Others Under Under Development Development
Thin-film
Dye sensitization PV
Solar Business Local Production for Local Consumption

North
America
C-Si
Module assembly
SMCA Memphis, TN 200MW/year Operating since 2003
200MW 100MW
2003
2008
2010
2011
Europe,
Africa and Middle East
Asia
and Oceania
Green Front Sakai, Osaka
Operation from Mar 2010 Initial capacity : - Thin-Film 160MW/year - C-Si 200MW/year C-Si TF
SUKM Wrexham, UK 500MW/year 3Sun Catania, Italy Operating since 2004 160MW/year
Module assembly Cell Production Module assembly
Katsuragi
710MW/year C-Si : 550MW/year Thin-Film: 160MW/year
Cell Production
TF C-Si TF
C-Si
500MW
220MW 110MW 20MW
Cell Production Module assembly
2. Technology of Glass-glass Thin-Film Silicon PV Module
Thin-Film Si PV
Glass-on-Glass Thin-Film Si PV module
1) Advantage of Thin-Film Si PV for Power Generation
1) Advantages of Thin-Film Si PV Modules

Thin-film Si cells use a hundredth of the silicon material in crystalline Si cells which are encapsulated in PV modules.
200m

2m
Crystalline Si Cell Thin-Film Si Cell
9
1) Advantages of Thin-Film Si PV Modules

Comparison with other thin-film PV modules
: Advantage
Comparison item Temperature coefficient of Power generation at high temperature region Module Conversion Efficiency (Mass Production basis) Rare metal risk Harmful substances risk Impact to BOS cost Because of Module size
Thin-Film Si
CdTe
CIS
-0.24%/degC
-0.25%/degC
-0.31%/degC
~ 10.0%
~11.0%
11.4~12.6%
None None 1.0 x 1.4m
Te Cd
In Se
1.0 x 0.6m 0.9 x 1.2m (e.g. Company A) (e.g. Company B)

10
1) Thin-Film Modules Unique Characteristics / Advantages

Good Power Generation Performance is expected in low latitude and high temp regions.
Why? (1) Air Mass Characteristics (2) Temperature Characteristics (3) Long-Term Reliability Suitable Area for Thin-Film Silicon PV Modules
Low
Mediterranean
lat
Maghrev
USA(CA/AZ) India Mexico
i tu d
es/ H
Saudi Arabia
i g h tem pre
Africa
ASEAN
Chile
gi on
South Africa
Australia
Brazil
Thin-Film Silicon PV Module has unique features to comply with customer demands for more energy production.
11
(1) Air-Mass Characteristics

TF PV has Higher Energy Conversion at Low-Latitude Sunlight
<Schematic of Air-Mass Characteristics>
Light Traveling Path in Air-Mass
Longer High Latitude
Red Light for Crystalline PV
Shorter
Low Latitude
Terrestrial Atmospheric Shell or Air-Mass
Blue Light for Thin Film PV
Shorter distance of light traveling path in the air, Blue color is rich in light irradiation. Conversely, long distance traveling makes Twilight at Sunset as red-rich light observing. Thin-Film PV has higher sensitivity in blue light which low latitude areas are rich in.
(2) Temperature Characteristics

Higher output is expected in high temperature regions
Actual operation at this temperature
TF
Relative Output
Specification at 25 c-Si
+30 rising in use
Module Temperature
Thin-Film: Lower drop-down as heated.

Power Generation Data Calculated with PV Syst. in Middle East

Calculated annual output power generation by PV systems
2000
PowerGeneration(kWh/kWp/year)
1800 1600 1400 1200 1000 800 600 400 200 0
City
AnnualPowergeneration ratio (ThinFilm/Crystalline) 108.9% 109.1% 109.4% 109.0% 105.7% 105.7%
Muscat,Oman
TFSi CSi
Abudhabi ,UAE Riyadh, SaudiArabia Dhahran, SaudiArabia
Muscat, AbuDhabi, Riyadh, Oman UAE Saudi Arabia
Dhahran, Saudi Arabia
Alger, Algeria
Tunis, Tunisia
Alger,Algeria Tunis,Tunisia
<Condition for our estimation>

City Muscat Abudhabi Riyadh Dhahran Alger Tunis Direction South South South South South South Latitude[N] Longtitude [N] Altitude[m]
The annual date shows very positive results.

Tiltangle[] AverageofTamb [] Effectiveirradiation [kwh/m2]
23.61 24.47 24.59 26.16 36.34 36.48
58.59 54.37 46.49 50.09 2.57 10.21
11 2 695 26 5 5
21 21 19 22 28 30
27.85 28.4 26.06 27.49 17.97 18.89 14
2133.5 2105.9 2146.0 2095.7 1764.0 1966.5
Important : The simulated output performance data by PV-Syst shown here are our raw measurement values and used for referential purpose only. In no event will Sharp be liable entirely or partially for any loss or damage whatsoever arising from, or in connection with, the use of the given figures here. The actual power generation is much influenced by the conditions of installation and environmental / climate circumstances.
Thin-Film Silicon Performance Demonstration Site : Malaysia

Purpose : Comparative observation of module output of Thin-Film and C-Si modules
Result : Better output yield compared to C-Si

Sharp Malaysia Building Thin-Film
<Condition>
Evaluation Module(TF)NA-F121G5 12(1.45kw) (C-Si)NU-S0E3E8 (1.44kw) Inclination:10 Azimuth : southeast Location: Selangor Darul Ehsan, Malaysia (close to Kuala Lumpur) Latitude:3.02 ,Longitude:101.56 Annual average Temp. 27degC
C-Si (mono)
Thin-film modules perform generally well compared to crystalline in high ambient temperature areas such as Malaysia.
[Actual data - Day]
Power (W) 1600 1400 1200 1000 800 600 400 200 0 7:10 AM Radiation (w/m^2) C-Si Thin Film Radiation 1600 1400 1200 1000 800 600 400 200
Over 12 months TF produces more power than c-Si (c-Si is 1) [Actual data - Month]
1.2 1.15
Power Generation Ratio(TF/C)
Power generation ratio Average temperature
35 30 25
Tamb /
1.1 1.05 1 0.95 0.9 0.85
20 15 10 5 0 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11
0 8:00 AM 8:50 AM 9:40 10:30 11:20 12:10 1:00 AM AM AM PM PM 1:50 PM 2:40 PM 3:30 PM 4:20 PM 5:10 PM 6:00 PM 6:50 PM
0.8
Time (hr)
TF PV Performance
15
(3) Long-term reliability due to Module structure

Highly advanced cell forming & scribing processes eliminate the potential risk of soldering failures.
Thin-film Modules
Forming Si layer by Forming Plasma CVD process Scribing into Thin-Film layer Scribing process unit cell strips by Laser No soldering points between unit cells
Current Si Layer Glass Substrate Current
Soldering points of a module: ~60
Crystalline Modules
Crystalline cell Output
15 times less than crystalline

Assumption: 72-cell/3-Grid Bus lines Output
Soldering points of a module : ~1000
2) Sharp Thin Film - Glass-glass -
17
Structure of Sharp Glass-glass Module

Robust sandwich structure of glasses with new encapsulation materials eliminates the possible risk of photovoltaic cell deterioration.
Cross Sectional view of Glass-glass Module

Glass-glass Glass-glassStructure Structure
Back Photovoltaic Cell Front FrontGlass Glass& &Back Backcover coverglass glass
Front
Our Ournew newdevelopment development High-Barrier High-Barrier Material Material Lower Moisture Vapor Transmission 1/30 compared to EVA No Edge Encapsulation needed due to the high immunity against moisture
(Edge encapsulation material of previous module is EVA + Butyl )
Long term reliability of Sharp Module

Damp-Heat Test
Requirement of IEC Standard
Glass/Glass Model Framed Model
100%
RelativeOutput Ratio
80% 60% 40% 20% 0% 0 500 1000 1500 2000 TestTime (h) 2500 3000
Glass/Glass model Glass/Glass Model
Framed Model Current model
High Temperature(85) and Humidity test85%RH Requirement of IEC Standard is more than 95% at 1000 hours
No performance loss is seen until 3,000 hours and beyond (test currently ongoing).
3. Mega-Solar Power Generation Plants
1) Special Features of Sharp Systems Solutions
20
PV Module: Glass-glass structure

Lower Energy Loss to increase power generation ~ Less dust accumulation Less Maintenance Less Possibility getting rusty
With Frame
Glass-glass structure (NS-F135G5)
Dust Dustaccumulated accumulatedon on the thebottom bottomside sideof offrame frame
Less Lessdust dustaccumulation accumulation with glass-glass with glass-glassstructure structure

21
Mounting Structure
Easy Installation Fewer Parts Pre-assemble before transportation to sites Highly Corrosion-Resistant Material for Mounting Structure
22
Monitoring System
Monitoring PV generation from a remote place by collecting output data and identifying system failures
13rd.Feb.2007 LCD Monitor ( ) RGB Extention cable
Monitor RGB Distributer
Sensor Solar Link Software From Grid

Transduser Box Junction Box Junction Box Junction Box
DC
Analog signal (DC4-20mA)
RS232C RS485
RS-485 RS-485
Inverter 1
Inverter 2
DC
Inverter 3
DC
RGB PC Solar Link
RS-485
Ethernet Communication Unit
Wh Mater
UPS
AC200V
HUB Router ADSL Laptop PC for maintenance
RS-485 3phase4wires AC400V (50Hz)
Distribution Panel
HQ Server
DATA
SHARP Data Center in Japan Router Web Server (for rental)
LAN
Web Access
Internet
Router
HP Web Server (linked to PV web server)
Guest PC (Browser)
Guest PC (Browser)
Office PC (Browser)
23
Operation & Maintenance (O&M )

Sharp cultivated the knowledge and skills of solar systems during its long experience in the industry.
Before and After
Establishing a maintenance company helps create job opportunities in the local community. Sharp could pass on its insights to the maintenance company in Saudi Arabia once established. SHARP will provide Product warranty Output warranty Performance ratio warranty (optional).
3. Mega-Solar Power Generation Plants
2) Examples of Mega-Solar Plants using Sharp Modules
25
NED Project (Thailand)
System size 73MWdc Location Lop Buri Province, Thailand 190 ha(1.9k) Scale Sharp supply Thin-Film module Inverter Mounting structure BOS Construction start from July 2010 Construction finished : March 2012 Electricity rate : $0.371/kwh(10years)
Lopburi Bangkok
26
Output of NED Project in Thailand

SHARPs EPC Project EGAT
(Electricity Generating Authority of Thailand)
EPC: Engineering, Purchasing, Consulting
PPA
OWNER
IPP
Project Finance (70%)
ADB: Asian Development B a n k
ADB
CLP
Mitsubishi Corp
33% 33% 33%
Equity (30%)
Local Bank
Kashikorn Bank
Natural Natural Energy Energy Development Development (NED) (NED)
EGCO
Bangkok Bank
EPC Lump-sum Contract Japan - Thailand Consortium SHARP SHARP Corp Corp
Design and Supply of PV Modules & Total System ITD/ITE Civil, Construction, Installation
Siam Commercial Bank
1. 1. SHARP SHARP and and ITD/ITE ITD/ITE form form the the consortium consortium to to provide provide EPC EPC 2. NED Owner in Multi Nation (Thailand/Hong Kong/JAPAN) 2. NED Owner in Multi Nation (Thailand/Hong Kong/JAPAN) 3. 3. The The first first Project Project Financed Financed Solar Solar Power Power Plant Plant in in Asia Asia
27 4thSSEF,May8and9,Riyadh
Maintenance Company:
(example in Thailand (NEDs Case))
Sharp Solar Maintenance Asia Co., Ltd. (SSMA)
Founded Investment Shareholder Actual performance Track record 21 March, 2011 1,000,000 baht Sharp Thai Co., Ltd. Sharp Corporation 73MWdc solar project (Thailand)
SSMA has access to the knowledge and skills of solar systems which Sharp cultivated during its long experience in the industry. Sharp could pass on its insights to the maintenance company in Saudi Arabia once established. SHARP will provide Product warranty Output warranty Performance ratio warranty (optional)
Ground water
Special water
Establishing a maintenance company also helps create job opportunities in the local community.
28
Technology: Thin-Film Site : California Capacity 6.3MWdc Installation year 2009
29
Technology: Thin-Film Site: California (Eurus Energy) Capacity : 57.7MWdc Installation year : 2011
30
Issues requiring discussions

1. Reducing the influence upon the frequency of the grid network caused by the reverse power flow from the PV systems connected 2. Countermeasure to reduce voltage and frequency fluctuation under the abrupt changes of irradiation 3. Establishing rules for grid connection
Thank you for your attention!
32

Tetsuya Watanabe Sharps Technology of Glass Glass Thin Film Silicon PV Module

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4th Saudi Solar Energy Forum, May 8th and 9th , Riyadh Saudi Arabia

Sharps Technology of Glass-glass Thin-Film Silicon PV Module

1. Brief Introduction of Sharp Solar Business

Solar Business Our History

Development Mass production of Space-use PV cells of PV cells

IEEE milestone recognition

1963 Sakai factory starts operation

2008 Mass production of large size tandem Thin-Film module starts

For higher For higher efficiency efficiency

For more For more cost effectiveness cost effectiveness

Super see-through ThinFilm PV module (Japan)

Mega Solar Power Generation installation (Thailand) 4

Solar Business Wide Range Products

Module See-through type

Thin-Film (Amorphous, Micro-crystal)

Solar street light

Mono-crystalline (GaAs) Compounds

Poly-crystalline (CdS,CdTe,CulnGaSe2, etc.) Dye sensitization

Off grid system

Others Under Under Development Development

Solar Business Local Production for Local Consumption

SMCA Memphis, TN 200MW/year Operating since 2003

Africa and Middle East

Cell Production Module assembly

2. Technology of Glass-glass Thin-Film Silicon PV Module

Glass-on-Glass Thin-Film Si PV module

2. Technology of Glass-glass Thin-Film Silicon PV Module

1) Advantage of Thin-Film Si PV for Power Generation

1) Advantages of Thin-Film Si PV Modules

1) Advantages of Thin-Film Si PV Modules

None None 1.0 x 1.4m

1.0 x 0.6m 0.9 x 1.2m (e.g. Company A) (e.g. Company B)

1) Thin-Film Modules Unique Characteristics / Advantages

USA(CA/AZ) India Mexico

(1) Air-Mass Characteristics

Red Light for Crystalline PV

Terrestrial Atmospheric Shell or Air-Mass

Blue Light for Thin Film PV

(2) Temperature Characteristics

+30 rising in use

Thin-Film: Lower drop-down as heated.

Power Generation Data Calculated with PV Syst. in Middle East

1800 1600 1400 1200 1000 800 600 400 200 0

AnnualPowergeneration ratio (ThinFilm/Crystalline) 108.9% 109.1% 109.4% 109.0% 105.7% 105.7%

Abudhabi ,UAE Riyadh, SaudiArabia Dhahran, SaudiArabia

Muscat, AbuDhabi, Riyadh, Oman UAE Saudi Arabia

Dhahran, Saudi Arabia

<Condition for our estimation>

The annual date shows very positive results.

23.61 24.47 24.59 26.16 36.34 36.48

58.59 54.37 46.49 50.09 2.57 10.21

27.85 28.4 26.06 27.49 17.97 18.89 14

2133.5 2105.9 2146.0 2095.7 1764.0 1966.5

Thin-Film Silicon Performance Demonstration Site : Malaysia

Result : Better output yield compared to C-Si

Power generation ratio Average temperature

1.1 1.05 1 0.95 0.9 0.85

(3) Long-term reliability due to Module structure

Soldering points of a module: ~60

15 times less than crystalline

Soldering points of a module : ~1000

2. Technology of Glass-glass Thin-Film Silicon PV Module

2) Sharp Thin Film - Glass-glass -

Structure of Sharp Glass-glass Module