SOPPOM Users Forum October 2013 - SIM-Flanders · 2014-01-15 · SIM Users’ Forum October 21 st...

SIM Users’ Forum – Antwerp October 21 st 2013Outline of the SOPPOM Program(Solution-based processing of photovoltaic modules)

SIM Users’ ForumOctober 21st 2013

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2012 was a strong year for PV installations …driven by EU, China, USA marketsGlobal cumulative installed capacity reached close to 100 GW

• Manufacturing of modules nearly left Europe (cost of manufacturing, production close to market, strategic national decisions, …)

• Concentration of the PV producers

• PV remains attractive for supplier of materials and high tech production equipment

• c-Si is more and more dominant (cost and performance) impacting thin-film PV & other technologies

• BIPV developing


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Global annual market of 30+ GW still expectedfor 2015 taking global cumulative installed capacit yto close to 200 GW by 2015

How will technologies share the “golden pot”?


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Drastic drop of c-Si ASP has impacted the wholePV industry

48%3.0%6.1%a-Si/µc-Si

210%3.0%1.7%CI(G)S

100%8.0%9.0%CdTe

CAGR 2006-2011 (%)

Share of total cells in 2011 (%)


TF tech.

48%3.0%6.1%a-Si/µc-Si

210%3.0%1.7%CI(G)S

100%8.0%9.0%CdTe

CAGR 2006-2011 (%)



TF tech.

� c-Si & related will continue to be dominant technol ogysince benefiting from better cost structure and eff iciency

� TF technologies can defend their share of the marke t provided cost isreduced (can non-vacuum processes help?) and effici ency is developped (reaching 18% on cell level in a non-vac uum process is the key major technical challenge to be overcome )


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End of day it will be about cost per m 2 & efficiencyfor technologies envisioning mass markets

80 GWp-35%TFPV by 2020

0

20000

40000

60000

80000

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

Ann

ual p

rodu

ctio

n (M

Wp)

OPVDSSC

CPVCdTeCIGSTF Si

c-Si

Total TFPV

(TFSi, CIGS, CdTe)

at 28GWp in 2020

CAGR = 30.5%

• R&D on materials is crucial in that respect • Business risk higher than at inception of SOPPOM• Technology risk higher as well (best result within SO PPOM 5% cell-level efficiency)• SOPPOM program based on strong generic competences aro und PV in Flanders• Specific competences on thin-film technology to be built on the go


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SOPPOM’s overarching objective is to drive down costs of thin-film PV CIGS & OPV through

ICON1:OPV ICON2: CIGS

• Increasing efficiency at the cell, module & system level (Wp/m 2)

- OPV: include inorganic CIGS or quantum dots in active layer (hybrid layer)Strategy not efficient, alternative investigated

- CIGS: Match traditional CIGS cell efficiencies with non vacuum equivalents

• Decreasing cost of production process (€/m 2)- By decreasing material cost through printing

of TCO-layers and CIGS layers (less spillage versus vacuum)

- By developing high throughput processes (printing, fast annealing& selenisation processes)

- By creating less expensive semiconductor materials (not currentfocus)


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SOPPOM is part of a more ambitious roadmap for PV development in Flanders

• Target efficiencies not sufficient for market readiness

• Cost must go further down

• Competences build-up takes time & resources

• Roadmap to be kept as a guide for rest of SOPPOM

• Any further program would reviewthis roadmap by adaptingresources, reinforcingcompetence build-up by international cooperation, …

• Business risk and business commitment to be reviewed


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Objectives are to be achieved through theinterplay of 7 R&D projects (4 SBOs & 3 ICONs)

SBO 1: abCIGS

Synthesis precursor, NP’sSurface chemistry

Stable printable dispersions CIGS & hybrid inorganic-organic

Annealing - CIGSCharacterization

Leader UGentKUL, UA, IMEC, Uhasselt, VUB

ICON 1 OPvTECH

Linear deposition process of multilayered stacksDesign, fabrication

and characterisation of multijunction OPV modules

Leader SolvayAgfa, IMEC, Uhasselt, AGC

SBO 3: phyCIGS

Cell integrationCell characterization

Cell modelingCell semiconductor physics

Leader IMECHelmholtz,KUL, Uhasselt,

Ugent, UA

ICON 2: CIGstack

Inks and formulations

Deposition technologiesRapid annealing

Leader AGCAgfa, Elsyca, Umicore,

KUL, UGent, Uhasselt, IMEC

Science axis S&T axis

Polyspec O-Line

SBO 2: weTCOat

Metal oxide screeningSynthesisprecursor, NP’s

Surface chemistryStable printable dispersions

AnnealingCharacterization

Leader UHasseltIMEC, KUL, UA, Ugent

Advanced in situcharacterization

Surface chemistry and annealing studies

NoVa CIGS

substratesOPV AGC

Basic TCO nanopowders

(Umicore)

SBO 1: abCIGS

Synthesis precursor, NP’sSurface chemistry

Stable printable dispersions CIGS & hybrid inorganic-organic

Annealing - CIGSCharacterization

Leader UGentKUL, UA, IMEC, Uhasselt, VUB

ICON 1 OPvTECH

Linear deposition process of multilayered stacksDesign, fabrication

and characterisation of multijunction OPV modules

Leader SolvayAgfa, IMEC, Uhasselt, AGC

SBO 3: phyCIGS

Cell integrationCell characterization

Cell modelingCell semiconductor physics

Leader IMECHelmholtz,KUL, Uhasselt,

Ugent, UA

ICON 2: CIGstack



Leader AGCAgfa, Umicore,


Science axis S&T axis

Polyspec O-Line

SBO 2: weTCOat

Metal oxide screeningSynthesisprecursor, NP’s

Surface chemistryStable printable dispersions

AnnealingCharacterization

Leader UHasseltIMEC, KUL, UA, Ugent

Advanced in situcharacterization

Surface chemistry and annealing studies

NoVa CIGS

substratesOPV AGC

Basic TCO nanopowders

(Umicore)

ICON 2: CIGstack



Leader AGCAgfa, Elsyca, Umicore,


ICON 3: SOL-CAP

Development of a multi-functionalsolar panel front encapsulant

Leader Novopolymers

A.Schulman Plastics, UmicoreKUL, IMEC, KaHo St-Lieven

SB04: APSYNC

Automated synthesisScaled up synthesis of CIGS, QD, TCOQSPR for CIGS, QD, TCOActive reaction steering

Leader FLAMACUGent, IMOMEC


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SBO1 activities on CIGS absorber

OBJECTIVES• Develop a lab scale non-vacuum process for the formation of CIGS absorber layers

• Understanding the different steps in the process

- Formation of nanoparticle colloids as precursors

- Analysis of nanoparticle surface chemistry

- Transformation of precursor film into dense CIGS film

- Modeling nanoscale transformation and annealing processes

CHALLENGES• Creating a well defined starting point

- Fully characterized nanoparticle colloids (particle composition, surface chemistry and colloid composition)

• Unravelling the magic

- Input-output relations in film transformation (ligands, particle morphology, particle composition, additives, …)

• Understanding what is happening

- Develop and implement models that describe NP film transformation

Outline of SBO1 abCIGSProject lead: Prof. Zeger Hens (UGent)


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OBJECTIVES• Incorporation of nanoparticles in the OPV bulk heterojunction to widen absorption window

• Reviewed to include other approaches with higher prospects of improving efficiency

CHALLENGES• Incorporation of nanoparticles into organic matrix

• Interaction between molecular additives and organic matrix

SBO1 activities on OPV layer

SIM Users’ ForumOctober 21st 2013 11

SBO2 activities on TCO layer depositionFOCUS

• The entire process of solution deposition of TCO (ITO & AZO) materials for inorganic(CIGS) TF PV and (hybrid) organic TF PV

OBJECTIVES• Obtain TCO thin films (30 – 1000 nm) by wet processing

- As front electrodes on glass and on CIGS stacks- With equal properties as currently obtained by vacuum deposition (>85% transparency,>1000 S/cm conductivity,...)

CHALLENGES• Preparation of dense, contamination free layers out of TCO-precursor solutions• Compatibility of deposition and annealing of a printed TCO layer on top of an underlying

CdS or CIGS layerPrecursor chemistry

TCO performance

TCO formation

Outline of SBO2 weTCOatProject lead: Prof. Marlies Van Bael (UHasselt)


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EMATmicrostructuralcharacterization

NMRdispersions

CoCooNanneal studies

IMO-IPCprecursor synthesis

depositions

IMO-MaPhmicroscopy

electrical properties

particles

dispersions

coatings

SBO2 – Interactions within project


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Synthesize various building blocks- Composition- Particle shape- Particle size- Particle size distribution- Surface chemistry

Study the effect on layer formationand properties

SBO2 – Experimental approach

Synthesize different precursor solutions

- Composition- Start product- Solvent- Type of chemical

reactions

Study the effect on phase formation and layer properties

+ hybridroute


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SBO3 activitiesCell processing & characterization

FOCUS

• Understanding the physics of CIGS PV cell stack: electro-optical properties

• Only study CIGS and TCO layers

OBJECTIVES

• Develop a baseline process for a CIGS solar cell stack to provide SBO1&2 with feedback about performance

• Build technological understanding, to allow an investment in cell integration capability (feedback to ICON2)

CHALLENGES

• Study the interactions between the different layers and annealing conditions on the basis of printing technology for CIGS and TCO layers

• Development of working cells to provide SBO1&2 with feedback

• Unravel link between material synthesis, ink/paste formulation and post deposition treatment as to obtain the maximal efficient CIGS module and to understand the up scaling issues

Outline of SBO3 phyCIGSProject lead: Dr. Marc Meuris (IMEC)


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SBO3 – Research strategy & team

WP1: Solar cell stack process development

• Imec: M. Meuris (solar cell processing steps and device)

• KULeuven/MTM: J. Vleugels (Selenization process/TCO anneal)

WP2: electrical and physico-chemical analysis

• UHasselt: J. Manca (SPM/AFM, EBIC, C-AFM,...)

• Kuleuven/FYS: A.Stesmans (ESR, band alignment,...)

• UA: J. Hadermann (TEM, HR-TEM,...)

WP3: Solar cell modeling

• UGent: M. Burgelmann (modeling)

Qualify baseline process (with HZB)

printed CiGS & baseline TCO

baseline CIGS & printed TCO

printed CIGS & printed TCO

Solar cell characterization

WP1: CIGS processing

WP2: Analysis• Physico-chem• Electrical

WP3:Solar cell modeling

SBO1CIGS

SBO2TCO

ICON2Upscale

Qualify baseline process (with HZB)

printed CiGS & baseline TCO

baseline CIGS & printed TCO

printed CIGS & printed TCO

Solar cell characterization

WP1: CIGS processing

WP2: Analysis• Physico-chem• Electrical

WP3:Solar cell modeling

SBO1CIGS

SBO2TCO

ICON2Upscale


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• Starting substrate

- Mo coated glass from AGC(in parallel AGC improves Mo layer)

• Deposition of absorber (CuInGa)

- Wet coating

• Selenization step

- Vacuum RTP system with H2Se and H2S

- Furnace with Se powder

• CuSe selective etch with KCN

• Deposition of CdS

- Chemical Bath Deposition

• Deposition of ZnO and TCO

- RF sputtering

- Wet coating

• Thermal evaporation of organics

- RTP in inert ambient

SBO3 – Process flow for CIGS


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Automated precision synthesis of nanocrystals

FOCUS

• Develop a process for the automated precision synthesis of nanocrystals

• Based on the transfer of lab-scale person-performed synthesis recipes from UGent and IMOMEC

• Focus on CIGS and TCO

OBJECTIVES & CHALLENGES

• Automated process

• Scaling up to provide ICONs with sufficient access to particles for formulation

• Constant specs

• QSPR

• Active reaction steering

Outline of SBO4 APSYNCProject lead: Dr. Guido Huyberechts (FLAMAC)


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ICON1 – Activities in OPV

FOCUS� Incorporating inorganic nanoparticles in organic semi-conducting layers as to

broaden the absorption spectrum and boost OPV cell efficiencies� Investigate other concepts such as interaction of additives with organic matrix� Printed TCO materials that are compatible with OPV systems

OBJECTIVES� Achieve higher efficiency OPV modules (eff >7%), by controlling morphology over

time and increasing the solar spectrum absorption (incorporate QD’s)� Reduce cost of the modules, by developing printable solutions for TCO’s

CHALLENGES� Achieving stable dispersions of inorganic nanoparticles or quantum dots for hybrid

solar cells� Achieving deposition and annealing of hybrid layers allowing in-line processing� Formulation of TCO's inks/ fluids with optimal properties on rigid substrates � Achieving appropriate interface between the TCO and the hybrid active layer

(TCO surface structure, adhesion and interface diffusion)

Outline of ICON1 OPvTECHProject lead: Dr. Patrick Françoisse (Solvay)


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ICON2 – Substrates & InksFOCUS

� Substrate with Mo-back electrodes and inks (CIGS & TCO), for a high-throughput deposition process

� Concept for an in-line layer activation (annealing/selenisation) process

OBJECTIVES� Deliver CIGS and TCO ink formulations

- With proper rheology for non-vacuum deposition- Resulting in functional films (10% efficiency) at acceptable thermal budgets

� Identify a deposition and annealing/selenisation technology concept, that allows for high throughput (>30 m/min) and low-cost (<1 €/Wp)

CHALLENGES� In-depth understanding of:

- Nanoparticle requirements with regard to high throughput deposition and transformation, and the respective synthesis technologies of NP’s

- The formulation of precursors in function of the deposition & annealing process- Debinding and annealing kinetics (allowing for in-line processing)

� Develop deposition & annealing/selenisation technologies to produce cells with reproducible and uniform PV results on a larger area.

Outline of ICON2 CIGStackProject lead: Dr. Daniel Decroupet (AGC)

in coll. with Dr. Dirk Van Genechten (Umicore)


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ICON2 – Workflow, partners & interactions

WorkflowCIGS precursor

Small scale annealing/selenisation

TCO precursorSmall scale annealing

Cell integrationCharacterisation

SBO 1 - UGhent

SBO 2 - UHasselt

SBO 3 - IMEC

Precursor supply

& scaling

Ink formulation

Depositiontechnology

DebindingAnnealing

Selenisation

Substratedevelopment

AGC

ICON 2

Umicore Umicore/Agfa Umicore/Agfa KUL (MTM)


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FOCUS

- Improving reliability of PV modules as well as improving their efficiency

OBJECTIVES

- Introduction of a multi-layer encapsulation approach allowing for improvedbarrier properties towards oxygen and moisture as well as allowing for improvedadhesion and modulus (softness) properties to reduce cohesive failure as resultof stress (delamination of PV stack)

� Lower production costs (less rework and production scrap) and longer modulelifetimes

- Introduction of a UV downshifting conversion polymer layer to improve efficiencyof the module

ICON3: Development of a multi-functional solar pane l front encapsulant

Outline of ICON3 SOL-CAPProject lead: Dr. Kristof Proost (NOVOPOLYMERS)

SOPPOM Users Forum October 2013 - SIM-Flanders · 2014-01-15 · SIM Users’ Forum October 21 st...

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