photon 3rd thin film conference heliovolt presentation_16feb11

© 2011 HelioVolt Corporation

Convergence of Markets:Growth of Distributed EnergyBJ Stanbery

HelioVolt Founder, Chairman of the Board and Chief Science Officer

November 2008


Energy Generation and the Terawatt (TW) Challenge• Humanity uses 12 TW of power today

– 1 TW = 1,000 GW (Gigawatts)

• World will need 15 TW by 2012

• Only 5 known sources of energy are available on a TW scale*– Fossil fuels: Coal, oil, gas

– Nuclear fuels

– Solar• Only inherently distributed solution

• No fuel cost*Prof. Nathan Lewis,

http://nsl.caltech.edu/

http://solar.physics.montana.edu/YPOP/Spotlight/Today/ultraviolet.html�


Solar Energy Reaching Worldwide Grid Parity

Source: McKinsey.(1) kWh = kilowatt hour; kWp = kilowatt peak; TWh = terawatt hour; Wp = watt peak; the annual solar yield is the amount of electricity

generated by a south-facing 1 kW peak-rated module in 1 year, or the equivalent number of hours that the module operates at peak rating.(2) Tier 4 and 5 are names of regulated forms of electricity generation and usage.(3) Unsubsidized cost to end users of solar energy equals cost of conventional electricity.

Annual solar energy yield (kWh/kWp(1))

Grid Parity as of(3)

Today

Size of electricity market TWh a year(1)

Aver

age

pow

er p

rice

per h

ouse

hold

($/k

Wh(

1))

1,000 1,500 2,000500

$0.3

$0.2

$0.1

$0.0

Cos

t per

wat

t at p

eak

hour

s ($

/Wp(

1))

China

India

Greece

Texas

Australia

SpainNew YorkFranceFinland

Japan

Germany

Sweden

Netherlands

Denmark

California Tier 4(2)

2020

California Tier 5(2)

Hawaii

Italy

California

$8.0

$6.0

$4.0

$2.0

Norway

United Kingdom

South Korea


0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

18,000

2004

2005

2006

2007

2008

2009

2010

E

2011

E

2012

E

32%45% 35% 29% 25%

42%

6% 9%

17%

22%

26%

Inst

alla

tion

s (M

W)

Germany Spain Italy ROE Japan S. Korea China ROW US

Policy Driven DemandUS % growth

Source: Barclays, IEA, Navigant

Historical Trends• 49% growth • 45% growth ex-Spain 2008

0%

50%

100%

150%

YOY Global Demand Growth

German FITSpanish

RDC

Recession

US ITC


Global Solar Markets in TransitionCommercial Roof Top Systems

Google HQ - California

Utility Scale

Solar farm - Germany

Austin City HallResidential roof - California

Building Integrated

Hong Kong Science Center

5


Advantages of thin film PV for Distributed Solar Energy• Efficient and high performing materials

– Direct bandgap semiconductors

– Better energy output – kWh/KW

– CIGS record at 20%+ conversion efficiency

• Significantly reduced costs– Less material usage

• Not affected by silicon supply shortages

– Potential for improving costs throughout value chain

• Advanced manufacturing techniques– Fewer processing steps

– Monolithic integration of circuits

– Automation

• Better aesthetics


BIPV Applications

• Roofing– Most common BIPV

application today

• Curtain wall / Facades– Emerging market

– HelioVolt has a number of established Joint Development partners

• Sunshades– Energy conservation and reduced building operating

costs

– Cooling load mitigation and glare control

– Easiest retrofit for PV but also costly

• Overhead glazing (canopies, skylights, atriums)


BIPV Product Requirements• Aesthetics:

– Visual attention – may or may not “blend into building”

– Uniform patterns and colors

– Must complement building design

• Efficiency:– Highest conversion efficiency per application

• Physical properties:– Flexibility in size

– Flexible and rigid • When glass = High quality flat glass

– Thermally or acoustically insulating

• Cost:– Smart integration


The Challenge to Wide Deployment of Distributed Solar Energy!

Growth of

BIPV

Builders

Developers/ Solar

Communities

Trades

Building Materials Mfgrs

Architects

PV Manufacturers

Government support

Standards Organizations


Opportunities for a More Efficient BIPV Products and Smarter Integration

10

Customer –Building Owner

Builder/ Contractor becomes Installer

Building Materials

Manufacturer becomes

Integrator/ System Designer

Future Integrated Products

Opportunity for Integration & System

Cost Reduction

Opportunity forPre-engineered

SolutionsPV Module

Mfgr

Mounting & Wiring

System Mfgr

Inverter/ Power Mgmt

Mfgr


Competitive Technology Advantage• FASST® CIGS process advantages

– Two-stage process provides maximum flexibility to optimize precursor deposition method and composition of each layer: higher efficiency

– Most rapid synthesis of CIGS from precursors of any method: reduces capital costs

– Demonstrated state of the art crystalline quality: higher efficiency

– Unique, rapid, flexible optimization of CIGS surface quality: higher efficiency

• Advanced NREL liquid precursor technology– Reduces capital costs and COGS

• Monolithic module circuit integration– Reduces module assembly costs compared to discrete cell assembly

• Advanced module packaging– Unique, high performance encapsulant, edge sealant, and potting

compound supports product lifetime beyond standard 25 year warranty: reduces cost of electricity (¢/kWh)

Glass In

Module Out

GlassPreparation

FASST® CIGSProcess

ModuleFormation

Final Assembly& Test

© 2011 HelioVolt Corporation 11


Reactive Transfer Processing of Compound Precursors

• Two-stage process– Low-temperature

deposition of multilayer compound precursor films

– RTP reaction of compound precursorsto form CIGS

112

Cu In, Ga

Se, S

247247

112 = Cu(In,Ga)(Se,S)2247 = Cu2(In,Ga)4(Se,S)7

CuSe.Cu2Se.

Cu2Se3. .(In,Ga)2(Se,S)3

.(In,Ga)4(Se,S)3

Intermetallic Plethora

.(In,Ga) (Se,S)


FASST® Reactive Transfer ProcessNon-Contact Transfer (NCT™) Synthesis

Source Plate

SubstrateCIGS Layer

Heat

Source Plate with Transfer FilmPressure

Substrate

Cu, In, Ga, Se

Process Step

• Independent deposition of distinct compound precursor layers on substrate and source plate

• Rapid non-contact reaction– Turns stack into CIGS with high efficiency structure– Combines benefits of sequential selenization with

Close-Spaced Vapor Transport (CSVT) for junction optimization

• CIGS adheres to the substrate and the source plate is reused

Rapid manufacturing process reduces capital amortization cost



FASST® CIGS Production Modules

Faceted CIGS crystals absorb light efficiently from all directions from dawn to dusk, giving HelioVolt CIGS its characteristic black color

Large grainswith no horizontal grain boundaries

support high efficiency

Cross-sectional SEM view

Top view with SEM

120x60 cm2 Module



Reactive Transfer Processing Compound Precursor Deposition• Two methods have been developed for

deposition of compound precursors– Low-temperature Co-evaporation

• Equipment requirements similar to conventional single-stage co-evaporation but lower temperatures lead to higher throughput and reduced thermal budget

– Liquid Metal-Organic molecular solutions• Proprietary inks developed under NREL CRADA

• Decomposition of inks leads to formation of inorganic compound precursor films nearly indistinguishable from co-evaporated films (for some compounds)


SEM

NREL CRADA – Hybrid CIGS by FASST®

Chalcopyrite CIGS (& Mo) (220/204) preferred orientation

achieved Exceptionally large grains Columnar structure

XRD


Product Scaling and Performance Experience

Prototype Module30cmx30cm

Scalability Proof

Production Module1.2mx0.6m

Commercial Production Size

Cell0.66cm2

14%

3%

3 Months

5%

12%

2 Months

2%

8%12%

10 Months

Cell

Prototype

Module Progress

1364x scale-up

8x scale-up

Effic

ienc

yEf

ficie

ncy

Effic

ienc

y4 Months



12% HelioVolt G2 Module Efficiency– NREL Measurement –

12% module independently verified by NREL (11.8±0.6%)



Total: $0.27/Wp

HelioVolt Process

Glass In

GlassPreparation

FASST® CIGSProcess

ModuleFormation


Competitors’ CIGS Cell-Based Processes

Monolithic Integration is Key to Cost Leadership and Product Reliability

$0.06

Module Out

$0.07

$0.01

$0.13

Note: Input materials cost / Wp in cents.

SubstratePreparation

CIGSProcess

Contact & GridFormation

Cell Cut & Sort

$0.06

$0.15

$0.01

?

Cell Stringing


Total: $0.51+/Wp

$0.12

$0.17

Glass In

Module Out

Additional Costs

Stainless steel foil

Higher non-material inputs (e.g. labor)

Higher yield loss

Stringing material

Two encapsulant layers and outer frame

$0.08

?

?

$0.12

$0.04

Add’l: $0.24+/Wp



• Development work based on HelioVolt patents and trade secrets will drive module efficiency from 10% to 16%

• Applied Research – HelioVolt’s partnership with NREL will drive module efficiency from 16% to 21%

6%

12%

18%

0%2010 2011 2012 2013

Baseline Process

Active Quenching,Advanced

Composition Grading Control

Ultrafast Heating,Predictive Design

Advanced TCO,Enhanced

Transmission,Light Trapping

Roadmap to 16% Module Efficiency



HelioVolt Module Rooftop Test Array

Factory Rooftop HelioVolt module test array. Array tracks performance of HelioVolt, as well as other thin-film and silicon modules, and inverters



Rooftop Performance –Comparison of All Arrays

• HelioVolt modules have highest yield, followed by Tier 1 mc-Si modules; CdTe & other CIGS lag behind

22

HelioVolt CIGSTier 1 mc-SiTier 1 CdTe2nd Glass Laminate CIGSTubular CIGS

One Day Comparison, All Arrays



Product Portfolio Built on Standard Component Platform

Commercial Rooftop Systems

BIPV – SpandrelsBIPV – Sunshades

Parking Structures

Utility Scale

• Front view• 5’x5’ Element• Framing provided by curtain wall manufacturer• Standard or custom element

1’X1’300mm CIGS PVIC

2’X4’

5’X5’



Solar Markets Expansion Will Drive Transition to Distributed Systems

• Capacity expansion to multi-GW scale essential to TW cumulative installation volumes– Primary obstacle to these expansions are capital-efficient

manufacturing technology

• Manufacturing technology breakthroughs and system integration continuing to drive low cost of solar energy– Product evolution destined to move beyond electronic component

integration to end-use systems integration

• Grid parity in global mass markets will be achieved in the next 5-10 years

photon 3rd thin film conference heliovolt presentation_16feb11

Technology

heliovolt corporationsource

energy generation

module assembly costs

global solar markets

annual solar yield

cost of electricity

peakrated module

capital costs glass