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with BNL to develop and then post live a Website (http://www.nrel.gov/cdte/) devoted to cadmium issues in PV. This site is now accessed frequently by companies and regulators concerned with this issue. We maintain that no issue of any substance stands in the way of the manufacture, use, or disposal of Cd-containing PV modules. Establishing this in the mind of key policy-makers and the public could be crucial to the survival and success of CdTe PV technology. Our insights were heavily used in a mid-year review of ES&H issues in Belgium, sponsored by the EU. Without our inputs, U.S. exports to the EU markets could have been stopped. We also worked on finishing a report on the effects of manufacturing thin films in super-large volumes with HP expert, Marvin Keshner. This report concludes that scaling up thin-film technologies will result in strong cost reductions that will allow systems under $1/Wp to be installed. The report is now available and is being requested frequently. Finally, we started the now ongoing testing of prototype thin-film modules in extremely hot and humid climates in Texas and Florida to discover vulnerabilities and try to feed back information on an ongoing basis to module suppliers so that modules can be fixed. In CdTe, the fiscal year saw progress in manufacturing, exclusively at First Solar. Company personnel installed almost an entire second generation of equipment at the Perrysburg, OH, plant, including cadmium chloride heat treatment, lamination, and scribing. They are also performing shakedown tests on their second- generation semiconductor coater. The coater is designed to improve uniformity and allow for higher materials utilization. During the year, First Solar has (1) continued to ramp up production and remains on track to produce over 20 MW in CY 2005 (6 MW in CY 2004); (2) continued outdoor and accelerated tests of CdTe modules to improve module designs and reliability; and (3) stated aggressive plans to replicate their successful 25-MW facility worldwide once it has reached a proper degree of reproducibility. They continue to sell a large fraction of their output to the German market, where they have been especially active in markets that demand the lowest cost systems per kWh of output—a major attainment for them and for thin films, in general, because most people’s recent perceptions of thin films (based on a-Si history) has been that they are for niche markets. Yet the goal of the Thin Film Partnership is energy significance, and niche markets can only be minor stepping stones to that achievement. It is important that a thin film has broken into large, distributed, and utility markets the way First Solar CdTe has done. As predicted by theory, the CdTe modules deployed by First Solar have better outdoor performance per installed watt-peak than c-Si systems, which is due to their reduced sensitivity to high operating temperatures. In addition, they seem to display a better low-light-level performance. The result is that their so-called performance ratio (kWh/kWp) is about 80% (Table 1)—a very high level. Table 1. First Solar CdTe Performance Ratios Location/ Type System Size (kW) Start Date Performance Ratio (PR) Current Month Total AZ-USA Field mounted 126.5 Jun-03 81.5% 81.0% AZ-USA Field mounted 129.0 Jul-03 84.7% 83.8% Perrysburg EZ-Mount 24.7 Sep- 03 86.2% 84.1% San Diego EZ-Mount 36.0 Jul-03 79.0% 79.9% Phoenix EZ Mount 3.0 Jan-04 87.7% 86.0% Phoenix EZ Mount 23.9 Apr-04 79.4% 80.6% Germany Roof Mount 17.9 Oct-03 80.8% 82.3% Germany Field Mount 105.7 Jan-04 85.5% 86.1% Germany Field Mount 97.0 Jun-04 85.9% 86.5% Germany Roof Mount 21.0 Oct-03 80.5% 74.9% Germany Roof Mount 28.5 Jun-04 87.7% 87.7% Our biggest concern with First Solar will be outdoor reliability, based on the paucity of data and the need for correlating accelerated tests with real performance. Because these remain challenges, we will maintain a high level of research focus on them.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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