Solar Module Manufacturing

Summary

This video script explores the fascinating process of solar module production, from extracting silicon from sand to creating efficient solar cells. It details the transformation of silica sand into high-purity silicon, the creation of ingots, and the slicing into wafers. The script highlights the importance of cleanliness and precision in solar cell production, where impurities are systematically added to form p-n junctions, enabling the flow of electrons and electricity generation. The video also showcases the assembly of cells into modules, capable of powering homes and large-scale solar plants, emphasizing the growing role of solar energy in the shift towards renewable energy sources.

Takeaways

• 🌞 Solar cells are a reliable way to produce electricity using the power of the sun without the need for operating supplies.
• 🏭 The production of solar modules is facilitated by integrated factories that include various stages from silicon extraction to module assembly.
• 🏜️ The process begins with silica sand, which is rich in silicon dioxide, the primary material used to extract silicon for solar cells.
• 🔥 Metallurgical grade silicon is produced by melting sand with carbon at high temperatures, resulting in a silicon purity of nearly 99%.
• 🧪 High purity polysilicon, necessary for solar power production, is achieved through a series of chemical processes including distillation and deposition.
• ⚙️ The addition of impurities like boron and phosphorus during the manufacturing process creates the necessary p-n junction for solar cells to generate electricity.
• 🔬 Producing solar cells involves a meticulous process that includes wafering, where silicon ingots are cut into thin slices for use in solar cells.
• 🔍 Quality control is crucial in solar cell production, with measures such as chemical treatments and high-temperature processes to ensure efficiency.
• 🔗 Solar cells are assembled into modules, which can then be installed in various settings to harness solar energy for power generation.
• 🌿 Solar power is not only cost-effective but also environmentally friendly, with modules producing energy that offsets their production costs within a few years.
• 🌐 The transition to renewable energy sources like solar is significant for the global energy supply, with large-scale solar plants contributing to this shift.

Q & A

What is the primary function of solar cells?

Solar cells produce electricity reliably and without the need for operating supplies, simply using the power of the sun.

How does GP Solar and SolIC contribute to the solar energy industry?

GP Solar and SolIC provide supporting services to enable the production of solar modules at a low price in integrated factories, making solar energy a more significant part of power production.

What is the starting material for producing solar-grade silicon?

The starting material is silica sand, which mainly contains silicon dioxide, from which silicon is extracted.

At what temperature is metallurgical grade silicon produced?

Metallurgical grade silicon is produced by melting silica sand with a carbon source at over 2,000 degrees Celsius.

What is the purity level of metallurgical grade silicon?

Metallurgical grade silicon has a purity of almost 99%.

Why is a higher purity level required for solar power production?

Solar power production requires a purity level of at least 99.999999% to ensure efficient electron flow and optimal solar cell performance.

How is the purity of silicon increased to meet the requirements for solar cells?

The purity is increased by liquefying the silicon, cleaning it through distillation, and depositing it onto a silicon seed sample in the poly silicon factory.

What is the role of boron and phosphorus in the production of solar cells?

Boron is added to the silicon during ingot production, and phosphorus is diffused into the silicon during cell processing to create two different layers that form a barrier for electrons, which is crucial for electricity generation.

How are silicon ingots produced?

Silicon ingots are produced by either solidifying multicrystalline silicon as a block or pulling a single crystal of monocrystalline silicon from molten silicon.

What is the purpose of the wafering process in solar cell production?

The wafering process cuts ingots into thin slices, called wafers, which are then used to produce solar cells.

How are solar cells transformed into modules in the module factory?

In the module factory, solar cells are placed in rows, soldered together, and connected to form modules. These modules are then protected with a sheet of glass, sealed, and tested under simulated sun conditions before being packed and shipped.

What is the significance of the energy payback time for solar modules?

Solar modules have an energy payback time of about 2 years, meaning they produce the energy required for their entire production, including setup, within this period.

Outlines

00:00

🌞 The Wonders of Solar Energy Production

This paragraph introduces the marvel of solar cells, which harness the power of the sun to produce electricity without the need for operating supplies. It highlights the collaborative efforts of companies like GP Solar and SolIC in providing services to make solar modules affordable and accessible. The script takes the viewer on a journey through an integrated solar factory, detailing the process from extracting silicon from sand to producing solar cells. The process begins with metallurgical-grade silicon, which is refined to a high purity level necessary for solar power production. The script emphasizes the abundance of silicon, the second most common element in the Earth's crust, ensuring a sustainable supply for solar energy production.

05:00

🔬 The Science Behind Solar Cells

This section delves into the science of solar cell production, explaining how the addition of boron and phosphorus creates a barrier that allows electrons to flow and generate electricity. It outlines the transformation of highly pure silicon into ingots, either multicrystalline or monocrystalline, and the subsequent production of wafers. The process is meticulous, with cleanliness being paramount to ensure cell efficiency. The script describes the steps in a clean room environment, where wafers undergo surface treatment and form the crucial barrier that defines the solar cell's positive and negative junction. The wafers then proceed to the cell production facility, where they are transformed into solar cells capable of harnessing the sun's energy.

10:03

🏭 From Silicon to Solar Modules

The final paragraph focuses on the assembly of solar cells into modules, which are the units that can be installed to generate electricity. It explains how cells are connected and protected with glass and foil to ensure a lifespan of over 20 years. The script also touches on the environmental benefits of solar power, noting that the energy used in production is offset within two years of operation. The paragraph concludes with a look at the larger impact of solar energy, with massive open-air plants contributing significantly to the global energy supply. It ends with an invitation for viewers to engage with GP Solar and SolIC for planning and implementing state-of-the-art solar factories, emphasizing the role of integrated and specialized production in advancing renewable energy solutions.

Keywords

💡Solar Cells

Solar cells are devices that convert sunlight directly into electricity using the photovoltaic effect. In the video, solar cells are the core technology that allows harnessing the power of the sun for electricity production. They are made from silicon and are part of a larger system that includes solar panels and modules, which are used in residential and large-scale power plants.

💡Silicon

Silicon is a chemical element that is the basis for most semiconductor materials, including those used in solar cells. The video explains that silicon is extracted from sand, specifically silica sand, which is rich in silicon dioxide. It is then purified to a very high degree to be used in the production of solar cells, highlighting its importance in the photovoltaic industry.

💡Purity

Purity in the context of the video refers to the lack of impurities in the silicon used to make solar cells. The script mentions that the silicon needs to be of a very high purity, at least 99.999999%, to be effective in solar power production. This is crucial as even trace amounts of impurities can significantly reduce the efficiency of solar cells.

💡Crystallization Furnace

A crystallization furnace is a piece of equipment used to melt and then solidify silicon into ingots. The video describes how chunks of polysilicon are placed in a crucible, melted, and then cooled in a controlled manner to form ingots. This process is essential for creating the solid base material from which wafers for solar cells are cut.

💡Wafers

Wafers are thin slices of semiconductor material, such as silicon, used in the manufacture of solar cells and other electronic devices. The video explains that ingots are cut into bricks and then into wafers, each less than 0.2 mm thick. These wafers are crucial as they are the foundation upon which solar cells are built.

💡Doping

Doping is a process in semiconductor manufacturing where impurities are intentionally introduced into the material to alter its electrical properties. In the video, boron is added to the silicon to create a P-type semiconductor, and phosphorus is diffused into the silicon to create an N-type layer. This creates a P-N junction, which is essential for the solar cell to generate electricity.

💡Photovoltaic Effect

The photovoltaic effect is the physical process by which light energy is converted into electrical energy. The video touches on this concept as it explains how solar cells produce electricity. When sunlight strikes the solar cell, the photovoltaic effect causes electrons to be freed and to flow, creating an electric current.

💡Module Factory

A module factory is where individual solar cells are assembled into larger units called modules. The video describes the process of connecting cells with similar electrical characteristics, soldering them together, and then encapsulating them with protective materials like glass and a backsheet. These modules are what end up being installed in solar power systems.

💡Energy Production

Energy production in the context of the video refers to the generation of electricity from sunlight using solar cells and modules. The script mentions that solar power is becoming an increasingly important part of power production, with large solar plants contributing significantly to the energy supply and residential installations providing electricity for homes.

💡Renewable Energy

Renewable energy is energy that is collected from renewable resources, which are naturally replenished on a human timescale, such as sunlight, wind, and rain. The video emphasizes solar power as a form of renewable energy, highlighting its role in the transition to cleaner and more sustainable energy sources.

💡Integrated Factory

An integrated factory in the context of the video refers to a comprehensive production facility that houses all stages of solar module manufacturing under one roof. This includes the production of silicon, the manufacturing of wafers, the creation of solar cells, and the assembly of modules. The script mentions GP solar and SolIC providing support for such integrated factories, indicating the scale and efficiency of modern solar production.

Highlights

Solar cells produce electricity using the power of the sun without any operating supplies.

GP solar and SolIC provide supporting services for the production of solar modules at a low price.

Solar energy is becoming a more important part of power production.

The process of making solar modules begins with sand, specifically silica sand, which is rich in silicon dioxide.

Silicon is the second most common element in the Earth's crust, ensuring a plentiful supply.

Metalogical grade silicon is produced by melting sand with carbon at over 2000 degrees Celsius.

The silicon produced still contains 1% impurities, requiring further purification for solar power production.

High purity silicon is achieved through a distillation process in tall towers, removing impurities.

Purified gas is transformed into highly pure silicon in semen reactors.

Boron is added to silicon to create a p-n junction, which is essential for solar cell function.

Phosphorus is diffused into the silicon to create an electric field that drives electron flow.

Solar cells are made from either multicrystalline or monocrystalline silicon.

The crystallization process in a clean room is crucial for the quality of the silicon ingots.

Wafers are produced by slicing ingots into thin pieces, less than 0.2 mm thick.

The production facility is treated like a clean room to ensure the purity of the solar cells.

Phosphorus diffusion and the printing of silver stripes are key steps in converting wafers into solar cells.

Modules are created by combining many cells to provide power for over 25 years.

Solar power is becoming more cost-effective, with large plants contributing significantly to the energy supply.

GP solar and SolIC offer planning and implementation services for integrated, state-of-the-art solar factories.

Transcripts

[Music]

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hello solar cells produce electricity

reliable and without the need for any

operating supplies simply with the power

of the

sun we are fascinated by this technology

together with many millions of people

who already draw electricity from the

Sun with big and small solar plants we

from GP solar and solic provide our

supporting services so solar modules can

be produced at a low price in huge

integrated factories and solar energy

can at last become a more important part

of power production I invite you to

discover the making of solar modules

together with

me an integrated solar

Factory with a production site for the

meterological

Silicon the big polysilicon

plant the crystallization furnace for

Ingot

production the wafer

production the solar cell production

side and the module

Factory there is also a central

administration

building as well as optionally a solar

cell

Academy and an own solar power

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plant in the beginning there is sand

silica sand to be exact since it

contains mainly silicon dioxide from

which we extract the precious silicon by

the way silicon is the second most

common element in the Earth's crust so

we won't run out of it together with

coal or other source of carbon the

Silicon sand is melted down at over

2,000 de C the result is metalogical

grade silicon with a purity of almost

99% when it cools down metalogical grade

silicon solidifies into a shiny Crystal

such as

these metallurgical great silicon can be

made of nearly any kind of

sand still it makes sense to use very

pure materials

here with a purity of already 99% may be

reached to produce it the silica sand is

put in a furnace together with a source

of

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carbon this alloy is melted down at

2000° using an electric Arc in this

process

the oxygen and silicon bonds are broken

and carbon dioxide and the Silicon that

we want to extract are

formed no great difference at first s

metalogical silicon and poly silicon but

this one still contains 1% of impurities

while solar power production needs a

purity level of at least

99.999999% such a high Purity can only

be produced by liquefying the Silicon

cleaning it by distillation and finally

depositing it onto a silicon seed

sample the metallurgical silicon will be

cleaned to a very high Purity in the

poly silicon Factory since it is very

difficult to clean it in its solid state

the chemical process is done the chunks

are Mill and liquefied and then this

fluid is cleaned in a distillation proc

process this happens in the high towers

that can be seen

here afterwards it is directed into the

so-called semen reactors and this is how

the purified gas is transformed into

highly pure silicon the gas is fed into

the reactor where it deposits on the

bars in order to process the Silicon in

the next step it is broken into pieces

again and then Carri it to the Ingot

Factory pure silicon the basis for our

solar power production is created but

how can we make the electrons flow in

the Silicon what makes our little water

pump work just with the power of the Sun

a silicon solar cell it can create

electricity because of this trick during

the manufacturing of ingots Boron is

added to the silicon and later during

the processing of a cell phosphorus is

diffused into the

Silicon as a result two different layers

are created

the region between the layers creates a

kind of wall for the

electrons they cannot get past this

barrier by themselves but by the help of

phon they can overcome

it now more and more electrons gather at

the upper side of the solar cell where

they push each other aside but they

cannot cross back because of the

barrier like connecting the upper and

lower side of the cell with a conducting

wire the electrons can return through

this

wire to this point we have produced

highly pure silicon this is also used in

the microelectronic industry in order to

produce solar cells impurities must be

added systematically at first Boron is

added afterwards an Ingot of silicon is

manufactured either as a block of

solidified multicrystalline silicon or

as a single Crystal of monocrystalline

silicon pulled from molten silicon both

are possible ways but in the following

we will have a closer look onto multi

line silicon

only for the first time we are in a

clean room the chunks of polysilicon are

filled in a crucible and then a vial of

barn is

added Al together it is brought into the

crystallization oven where it is

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melted by regulating the cooling it is

possible to remove unwanted

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substances once the Silicon has

solidified The Crucible is removed and

the Ingot is carried to the nearby wave

effect

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just gently pressing and the cooked egg

is split into many

slices the next production step The

wafering Works in a similar way the

first cutting creates bricks with the

correct Edge

length these are then cut into VAR s

slices each less than .2 mm thick these

Wafers are then used for producing Sol

cells the wafering is done in two

steps at first the Ingot this large

block coming from the Ingot Factory is

cut into

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bricks then these are pushed through a

wire

saw in it a several hundred kilomet long

wire carrying the so-called slurry is

put through the

brick it contains finest parts of

silicon

carbide which cut the Wafers out of the

brick they are then cleaned in a bath

and afterwards carried to the nearby

cell

production we have now passed through

the first factories and our silic sand

has turned into these wafers in a

factory like this The crucial part of

the barrier in the solar cell is formed

and thereby the positive negative

Junction in the cell is created during

this process cleaniness is of utmost

importance since even low levels of

impurities cause a bad efficiency of the

cell for this reason the production

facility is treated like a clean room

and The Operators Must ALL wear special

overalls to get such a solar cell in the

end and the wafer must run through the

following

steps here the Wafers

arrive several measuring devices

guarantee a high quality of the end

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product then the surface of the wafer is

roughed by running them through a

chemical

fluid

now in an oven at

900° the important step occurs which

converts the semiconductors into a solar

cell phosphorus is diffused into one

side of the

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cell in order to be able to pick up the

electrons later on a grid of fine silver

Stripes is printed on the

cell now several cameras examine the

cells to check the result and to measure

the cell

efficiency finally the cells are sorted

by certain criteria and then carried to

the module

Factory by now each cell can already

produce electricity in order to obtain

greater power output and to offer long

lifespan many cells are packed together

in modules now they can provide Power

for 25 plus years simply once they are

exposed to

sunlight by the way in about 2 years

they have produced the energy that is

needed for the entire production

including setting up they can be mounted

on facades on rooftops or even in great

open air plants how these modules are

produced can now be seen in the

animation of our sixth and last

Factory in the beginning of the module

Factory there are packages of solar

cells each containing cells with similar

electrical

characteristics they are first placed in

a row and then soldered

together then these rows are placed next

to each other and

connected in order to ensure that the

module can produce electricity during

its entire lifespan of more than 20

years a sheet of glass is used for

protection and an extra foil repeals

water then the modules are bonded in an

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oven a flash simulating the sun under

standard conditions tests the modules

before they are packed and shipped to

the

customer about 3 watt can be produced by

one solar cell more than 200 by a module

an ordinary rooftop is big enough for

approximately 5 KW

so an average house will produce more

electricity than the residents can use

solar power is also getting cheaper in

plants with several megawatt have been

built in Open Spaces functioning as

entire power plants they Harald the

change to renewable energies and already

represent a significant part of our

energy Supply the modules are produced

in highly specialized and increasingly

integrated factories GP solar and solic

would be delighted to help you in

planning and implementing an integrated

state-of-the-art

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Factory

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