The SAI PV Technology Incubator Program is designed to accelerate technologies/prodesses that have successfully demonstrated a proof-of-concept/process in a laboratory

Greene, L.

Keyes, B.

Mitchell, R.

Stephens, S.

Symko-Davies, M.

Ullal, H.

von Roedern, B.

UNT Digital Library

 A national laboratory of the U.S. Department of EnergyOffice of Energy Efficiency & Renewable EnergyNational Renewable Energy Laboratory Innovation for Our Energy Future Solar America Initiative (SAI) PV Technology Incubator Program Preprint  B. Keyes, M. Symko-Davies, R. Mitchell, H. Ullal,  B. von Roedern, and L. Greene National Renewable Energy Laboratory S. Stephens U.S. Department of Energy Presented at the 33rd IEEE Photovoltaic Specialists Conference San Diego, California May 11–16, 2008 Conference Paper NREL/CP-520-42540 May 2008 NREL is operated by Midwest Research Institute ● Battelle     Contract No. DE-AC36-99-GO10337  NOTICE The submitted manuscript has been offered by an employee of the Midwest Research Institute (MRI), a contractor of the US Government under Contract No. DE-AC36-99GO10337. Accordingly, the US Government and MRI retain a nonexclusive royalty-free license to publish or reproduce the published form of this contribution, or allow others to do so, for US Government purposes. This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights.  Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof.  The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at http://www.osti.gov/bridge Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone:  865.576.8401 fax: 865.576.5728 email:  mailto:reports@adonis.osti.gov Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone:  800.553.6847 fax:  703.605.6900 email: orders@ntis.fedworld.gov online ordering:  http://www.ntis.gov/ordering.htm Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste THE SOLAR AMERICA INITIATIVE (SAI) PV TECHNOLOGY INCUBATOR PROGRAM   Brian Keyes, Martha Symko-Davies, Rick Mitchell, Harin Ullal, Bolko von Roedern, Lori Greene and Scott Stephens1  National Renewable Energy Lab 1617 Cole Blvd., Golden, CO  80401 1 U.S Department of Energy    INTRODUCTION  The Solar America Initiative (SAI) PV Technology Incubator Program, funded by the Department of Energy (DOE), through the National Renewable Energy Laboratory (NREL), has the objective of shortening the timeline for companies to transition prototype and pre-commercial PV modules into pilot and full-scale manufacture. Entrance opportunities for the Incubator project are anticipated every 9 – 12 months as funding become available.  This program targets US small businesses with a minimum entrance criterion of a demonstrated PV cell process, lab device or module.  The successful exit criterion is anticipated to be prototype modules and pilot production demonstration of approximately 3MW/year.  Ten U.S. Small Businesses received subcontracts from NREL in the fall of the calendar year 2007, averaging approximately $3.0 million each of NREL/DOE funding over an 18-month period.  The subcontracts were awarded in two 9-month phases with the second phase of funding contingent upon successful completion of the first phase deliverables and a Stage-Gate review.  The award winners represent a diverse range of technologies including: polycrystalline thin-films; thin- and wafer-silicon devices; high-efficiency III-V devices; thin-film organics; and concentrating systems.  SAI PV INCUBATOR OVERVIEW  The SAI is an integral part of the President’s Advanced Energy Initiative (AEI).  The AEI is designed to reduce the nation’s dependence on foreign sources of energy by promoting broader research and development (R&D) to achieve substantive breakthroughs in a variety of energy resources, including solar photovoltaic systems. The SAI, authorized under the Energy Policy Act of 2005, represents a significant enhancement of DOE’s business strategy of partnering with U.S. industry to accelerate commercialization of photovoltaic (PV) system R&D to meet cost and installed capacity goals.  These SAI goals are to 1) substantively accelerate development of U.S.-produced PV systems so that PV-produced electricity reaches parity with the cost of electricity in select grid-tied target markets across the nation and 2) expand the U.S.-installed domestic capacity of PV systems to 5-10 gigawatts (GW).  The Solar Energy Technology Program’s (SETP) Posture Plan, http://www.eere.energy.gov/solar/solar_america/ about.html, illustrates how the SETP aligns with the SAI mission and the President’s Advanced Energy Initiative.  In order to accomplish the goals of the SAI, a multi-tiered, multi-phased program was established that addresses the near-, mid-, and long-term technological and scientific advances for improved performance, lower cost, and improved reliability of PV system components and installed systems.  The SAI PV Technology Incubator Program is designed to accelerate technologies/processes that have successfully demonstrated a proof-of-concept/process in a lab, but are not yet mature enough for large-scale commercial production.  The emphasis is currently on the barriers to enter commercialization by 2010.  Prototypes of these PV systems and components will be produced on a pilot-scale in a relevant operational environment with their demonstrated cost, reliability, or performance advantages.  PV and CPV modules are targeted in this phase of the technology development pipeline with goals that include the more efficient use of materials, better performance, higher reliability and improved manufacturing.  Details on the current solicitation requirements can be found at http://www1.eere.energy.gov/solar/solar_america/pv_incubator.html   EXISTING SUBCONTRACTS  Ten U.S. companies were awarded subcontracts through a competitive merit-review based process.  The resulting projects include a diverse set of technological approaches: Inexpensive and Thin Film Si; Low and High Concentration; Innovative Thin Film Manufacturing; and Low Cost Multi-Junction Cell Production.  The $27M in DOE funds represents 29% of the $93M worth of research and development taking place under the PV Incubator Program.  The current subcontracted projects are listed below:  AVA Solar AVA Solar has demonstrated fully automated, continuous in-line fabrication of CdS/CdTe PV. This project will enable the demonstration of extremely low manufacturing and equipment costs, improved module  1efficiencies and the ability for rapid manufacturing capacity expansion.  Blue Square Energy Manufacturing of thin crystalline silicon solar cell by growing a high purity silicon layer onto a low cost metallurgical grade silicon substrate. This approach can produce the high performance and reliability of traditional solar cells with reduced material utilization and manufacturing costs.  CaliSolar Production of cost-effective solar cells from low-cost, abundant, but impurity-rich Si feedstock materials. The focus will be on a novel and adapted metallization method specifically suitable for the use of metallurgical Si to manufacture solar cells with over 17% efficiency using multicrystalline Si within the next 18 months.  EnFocus Engineering A lightweight, low profile, high concentration PV module which is fully encapsulated and protected from wind, hail, dust and moisture. This module will utilize high efficiency multi-junction cells to generate higher power outputs in area-constrained applications such as rooftops.  MicroLink Devices MicroLink Devices will develop a low-cost, high efficiency dual-junction GaAs-based solar cell for use in 500x concentrator systems. The developed solar cell minimizes GaAs material usage while improving heat dissipation with a potential to reduce cost by 50%.  Plextronics Commercialization of Thin-Film Organic Photovoltaic (OPV) Technology. Plextronics will develop higher efficiency cells while increasing module lifetime design to enable this ultra low cost material to compete with traditional PV technology.  PrimeStar Solar Develop commercial CdTe module production based on the NREL 16.5% world record CdTe laboratory solar cell technology. The increased module energy conversion efficiency will lower installation costs and open new markets for CdTe based thin film modules.  Solaria  Solaria¹s PV-multiplying process yields two to three highly efficient cells from one, via solar cell singulation and optical amplification. Solaria’s DOE project aims to produce a non-tracking standard module form factor with 2-3X concentration manufactured in a reliable high volume automated process.  SolFocus 500x concentrating PV module emphasizing high reliability and high efficiency to enable large-scale commercial and utility market penetration. A folded reflective design allows for a high optical efficiency and acceptance angle in a compact frame. SoloPower Development of an electroplating-based, high-efficiency, low-cost CIGS cell and module manufacturing technology. Advantages of this deposition technique include lower equipment costs, reduced processing times and increased material utilization.  Detailed results from the funded activities will be made available in the publicly released Final Technical Reports.  CURRENT AND FUTURE SOLICITATIONS  The current PV Incubator subcontracts will undergo a Stage-Gate review during the summer of 2008.  At this time an evaluation of progress will occur and a determination to continue with the second 9 month phase of the subcontract will be made.  A second PV Incubator Solicitation occurred in early 2008 and those responses are currently being reviewed.  It is anticipated that the new round of subcontracts will be finalized in late summer of 2008.  Finally, as mentioned above, future entrance opportunities for the Incubator project are anticipated every 9 – 12 months as funding opportunities become available.  This would put the next solicitation in early 2009.  ACKNOWLEDGEMENTS  This work was supported by the U.S. Department of Energy under Contract No. DE-AC36-99GO10337 with the National Renewable Energy Laboratory.  2F1147-E(09/2007) REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 The public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to Department of Defense, Executive Services and Communications Directorate (0704-0188). Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ORGANIZATION. 1. REPORT DATE (DD-MM-YYYY) May 2008 2. REPORT TYPE Conference Paper 3. DATES COVERED (From - To) 11-16 May 2008 5a. CONTRACT NUMBER DE-AC36-99-GO10337 5b. GRANT NUMBER  4. TITLE AND SUBTITLE Solar America Initiative (SAI) PV Technology Incubator Program: Preprint 5c. PROGRAM ELEMENT NUMBER  5d. PROJECT NUMBER NREL/CP-520-42540 5e. TASK NUMBER PVB77201 6. AUTHOR(S) B. Keyes, M. Symko-Davies, R. Mitchell, H. Ullal, B. von Roedern,  L. Greene, and S. Stephens 5f. WORK UNIT NUMBER  7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) National Renewable Energy Laboratory, 1617 Cole Blvd.,  Golden, CO 80401-3393 U.S. Department of Energy, Washington D.C. 8. PERFORMING ORGANIZATION REPORT NUMBER NREL/CP-520-42540 10. SPONSOR/MONITOR'S ACRONYM(S) NREL 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)  11. SPONSORING/MONITORING AGENCY REPORT NUMBER  12. DISTRIBUTION AVAILABILITY STATEMENT National Technical Information Service U.S. Department of Commerce 5285 Port Royal Road Springfield, VA 22161 13. SUPPLEMENTARY NOTES  14. ABSTRACT (Maximum 200 Words) The Solar America Initiative (SAI) PV Technology Incubator Program, funded by the Department of Energy (DOE), through the National Renewable Energy Laboratory (NREL), has the objective of shortening the timeline for companies to transition prototype and pre-commercial PV modules into pilot and full-scale manufacture. Entrance opportunities for the Incubator project are anticipated every 9 – 12 months as funding become available.  This program targets US small businesses with a minimum entrance criterion of a demonstrated PV cell process, lab device or module.  The successful exit criterion is anticipated to be prototype modules and pilot production demonstration of approximately 3MW/year. 15. SUBJECT TERMS PV; Solar America Initiative; module; manufacturer; incubator program;  16. SECURITY CLASSIFICATION OF: 19a. NAME OF RESPONSIBLE PERSON  a. REPORT Unclassified b. ABSTRACT Unclassified c. THIS PAGE Unclassified 17. LIMITATION OF ABSTRACTUL 18. NUMBER OF PAGES  19b. TELEPHONE NUMBER (Include area code)  Standard Form 298 (Rev. 8/98) Prescribed by ANSI Std. Z39.18 

Solar America Initiative (SAI) PV Technology Incubator Program: Preprint

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Solar America Initiative (SAI) PV Technology Incubator Program: Preprint

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