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The prospect of solar grid parity is becoming more of a
reality every day. In 2010, the LCOE (levelized cost of electricity) for PV
solar was $.150/kwh, fairly close to other sources - nuclear is $.10, coal is
$.08, and natural gas is $.064.
Particularly responsible for this movement is the
significant drop in the cost of manufacturing solar panels. Currently,
commercial plants can produce electricity at $3.00 to $3.50 per watt, with solar
panels attributing only a third of that cost.
<--Image Credit: ArrayPower
But the drive continues for solar companies to bring prices
down and efficiencies up. In the past month, three startups have taken some steps
towards further advancement of this technology.
From Sawing to
Peeling
Conventional silicon solar manufacturing can produce three
solar-cell wafers from a millimeter of silicon. It requires sawing blocks of
crystalline silicon into wafers around 180 micrometers thick. This cutting
technique produces silicon sawdust equivalent to a 100-150 micrometer layer.
The sawdust is discarded as waste in most cases.

Astrowatt is a startup company looking to reduce the amount
of wasted silicon, which is still the most expensive item for solar-panel
manufacturing. Its new process saws wafers nearly a millimeter thick, and then
modifies the top of each wafer to act as a back of a solar cell with a later of
metal deposited on it. The wafer is then heated, causing stress and cracking from
expansion. From this, the engineer can peel off a 25-micrometer silicon-metal
film. The end result is multiple thin films and a thicker one which can be
recycled back into the process.
The metal backed film (shown right - Credit: Astrowatt) is
said to be more durable than past attempts to make thin wafers using other
methods. However, the films tend to curl up slightly, which could present
difficulty in handling during production. This could be detrimental to the feasibility
of this process, since current machinery is built for stiff/flat cells.
A Simpler Inverter
Current large-scale solar plants use either a single "central"
inverter or a number of "string" inverters to convert from DC (from solar
panels) to AC (grid-ready power). Both approaches suffer lower efficiencies
because the connection limits the output of the system to the level of its
lowest-producing panel.
ArrayPower is a startup company seeking to maximize power
through the use of a new inverter mounted to each panel. Microinverters, which
are similar in function, maximize the output of each cell, increasing system
output from 3 to 10 percent. They are typically more expensive, however, and
yield single-phase current which is only suitable for residential use.
The new "sequenced" inverters are of a more simple design
and utilize the system to carry out the filtering and smoothing. The creation
of three-phase current rather than single-phase allows the inverter's to store
smaller amounts of electricity for shorter durations. This means cheaper and
longer lasting inductors can be used in place of capacitors for energy storage.
Experts say that the technology, though promising, needs longer field trials to
test the long-term durability of the devices.
Smaller Is Better
While most solar cells are made from silicon, a better absorbent
used in smaller cells is gallium arsenide. But the costs of this material - along
with required optics, cooling systems, and tracking systems - make concentrated
solar modules much more expensive.

Semprius, a startup attempting to lower these costs, boasts
that its miniscule solar cells are much better at dissipating heat, making them
much cheaper. Third-party tests have also certified the concentrated solar
panels at 33.9 percent efficiency, making them the most efficient commercially
designed solar panels to date. Conventional silicon panels convert less than 15
percent of light into electricity.
Shown left is an array of solar modules on a two-axis solar
tracker, built by Semprius for testing. (Image Credit: Semprius)
The production process forms tens of thousands of tiny solar
cells on a single wafer of gallium arsenide. Then chemical etching and a
robotic system transfer each layer to an inexpensive substrate. The same wafer
is used many times, reducing costs and making the concentrated module more
attractive.
However, other important factors regarding the technology were
not mentioned, including the expected lifetime, the transportability, and the fragility
of the new design.
Looking Forward
The solar industry, which is going on 20+ years of
experience with silicon cells, proves that it takes a substantial amount of time
for new technologies to develop to a competitive level. The energy industry
cannot expect one breakthrough technology to solve all the problems of tomorrow's
"energy crisis". It's the little steps made over time that will make the
difference.
No doubt some of these startups may fail with oversupply and
reduced manufacturing costs, but ultimately my hope is that solar power
technology will continue to grow on its own and make a noticeable impact in
both the residential and commercial sectors.
Sources:
Concentrated
Solar Startup Sets a New Efficiency Record
Technology
Review - Device Could Drive Down Solar's Cost
Technology
Review - Startup Makes Peel-Off Solar Cells
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