SEMI Northeast Forum

The Impact of Materials on PV Technology

Stanley Merritt Global Business Development Manager DuPont Photovoltaic Solutions

September 28, 2011

© DuPont

To be the world’s most dynamic science company,

creating sustainable solutions

essential to a better, safer, healthier life for people everywhere.

The Vision of DuPont

We are a market-driven science company.

© DuPont

DuPont is a Global Leader in PV Materials

Cell Materials

Module Materials

Balance of SystemMaterials

Teflon®

frontsheets

Elvax®

IonomerPVBencapsulants

Solamet®

metallizations

Kapton®

substrates

Niapure®

sodium metal

Tedlar®

films for backsheet

Rynite®

frames

Kalrez®

Zalak®

parts & seals

Vespel®parts

Kapton® photo courtesy of Solarion AG

© DuPont

2010 2016

FS Ag13%

Backsheet10%

Encapsulant7%

Glass7%Silicon

44%

Jcn Box6%

Other13%

Metaliz's15%

Glass10%

Other10%

Backsheet13%

Silicon38%

Encap Film9%

Jbox-Inverter3%

Wet Chem1%

FntSheet1%

Other25%

Jcn Box5%

Frame16%

Gases/ Targets

10%

Substrate26%

Encapsulant7%

Backsheet11%

Frontsheet28%

Substrate7%

Cell (Gases/ Targets)

41%

Jcn Box9%

Encapsulant4%

Backsheet11%

Addressable Market in PV Materials

High EfficiencyStandard

CIGSa-Si

c-Si ModulesBill of Materials

TF Flex ModulesBill of Materials

$37B$37B$17B$17B

$1.2B$1.2B$0.3B$0.3B

Source: DuPont

© DuPont

Materials Cost Impact on PV Cells & Modules

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Crystalline Silicon Thin Film

Silicon Metal(42%)

Cost ofMaterialsin US$/W

Metal Paste (17%)

Backsheet (10%)

Front Glass (10%)

Encapsulant (7%)Junction Box (3%)Other Mat’ls (11%)

TCO Front Glass (36%)

Module Frame (13%)

Backsheet (18%)

Targets (7%)

Encapsulant (5%)

Junction Box (5%)Gasket/Edge Seal (4%)Packaging (2%)Other Materials (3%)

Source: DuPont

Bill of Materials

Gases (6%)

© DuPont

Materials Impact Three Critical Areas Essential to Achieving Grid Parity

1. Efficiency 2. Lifetime 3. Cost

Drive Lower PV LCOE to Achieve Grid Parity

© DuPont

Grid Parity Expected in Most Major Electricity Markets by 2020

ItalyBrazilSpainMexico

ChinaJapanIndia

GermanyUK

AustraliaFrance

S.KoreaTaiwan

Canada

USARussia

S. AfricaIran

UkraineSaudi Arabia

ItalyBrazilSpain

JapanGermany

USAIndia

ChinaCanadaTaiwanAustralia

MexicoFrance

S. KoreaUK

RussiaS. AfricaUkraine

Saudi Arabia

Iran

Note: Electricity usage in Top 20 countries accounts for 80% of global demand Source: Q-Cells

2020+ 2020+

Industrial Markets at Grid ParityResidential Markets at Grid Parity

© DuPont

11

6.610.2

0

5

10

15

20

25

UnsubsidizedPV Cost

Avg Resid'l gridprice (2010)

UnsubsidizedPV Cost

Avg Comml gridprice (2010)

UnsubsidizedPV Cost

Avg Industrialgrid price

(2010)

Achieving Grid Parity in the U.S. Requires ~50% Further Reduction in PV LCOE

PV LCOE and

Grid Price (US ¢/kWh)

~14c/kWh(CdTe)

(Large Scale)

~23 c/kWh(c-Si)

(Small Scale) 52%

53%

Residential UtilityCommercial

~19 c/kWh(c-Si)

(Med Scale)46%

Source: DuPont, US DOE

© DuPont

Roadmap to Grid Parity – Industry Technology Roadmaps

SystemCost

ModuleLifetime

Bankable Capacity >10 GW

<$2/W< 8 cents/kWh

PV LCOE

20-25 yrwarranties

30-40yrwarranties

2010 2011 2012 2013 2014 2015Timeline

AverageModule

Efficiency

14% 21%c-Si

TF 10% 14%

Standard Selective Emitter Back Contact

Tandem Junction High Efficiency Tandem

TF Flex 6% 13%

a-Si on Flex CIGS on Flex Roll-to-Roll CIGS

25-30 yrwarranties

Retail Grid Parity in portions of EU & US

© DuPont

Key Drivers of PV Levelized Cost of Electricity

PV LCOE

• System Efficiency• System Life• Insolation• Annual Degradation• Shading• Low-light performance• Component failures

÷

• Modules• BOS• O&M• Financing

SystemRevenue

IRRIRRSystem

Cost

Lifetime Power Output

© DuPont

Materials Impact Three Critical Areas Essential to Achieving Grid Parity

1. Efficiency 2. Lifetime 3. Cost

Industry roadmap to 20+% c-Si cells,

enabled bynew materials

Robust materials enabling >25 year

module lifetimes with high performance

Lower cost, light- weight polymers to replace glass and

metals

© DuPont

1. Efficiency 2. Lifetime 3. Cost

Industry roadmap to 20+% c-Si cells,

enabled bynew materials

Robust materials enabling >25 year

module lifetimes with high performance

Lower cost, light- weight polymers to replace glass and

metals

© DuPont

PV Technology Roadmap: c-Si Cells/Modules

High Efficiency Cells

Selective EmitterLocal BSF

Rear PassivationN-type Wafers

Conventional Cells

Back Contact Cells

Metal Wrap-thruEmitter Wrap-thruInterdigitated BC

>20%Module

Efficiency

~14%Module

Efficiency

Source: DuPont

2005-2011 Improved metallization pastes have enabled improvements in conventional cell designs ~1.5% / year (relative)

2011-Future Additional metallization improvements required for new cell designs

© DuPont

1. Efficiency 2. Lifetime 3. Cost

Industry roadmap to 20+% c-Si cells,

enabled bynew materials

Robust materials enabling >25 year

module lifetimes with high performance

Lower cost, light- weight polymers to replace glass and

metals

© DuPont

PerformanceUltra Violet (UV)

Temperature

Corrosion

Electrical Insulation

• Transmitted• Reflected

• Peak• Cycling

• Precipitation• Humidity

• Shock• Shorting

Backsheet Requirements

Reliability

Durability

Safety

Time

Pow

er O

utpu

tPo

wer

Out

put

Time

1: Ross, R. G., Jr. and Smokler, M. I. (1986) Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final report. Volume VI: Engineering sciences and reliability. JPL Publication, 86-31, volume VI. NASA , Springfield, VA2: Joint Research Centre (JRC), The Results of Performance Measurements of Field-aged c-Si Photovoltaic Modules, Prog. PV: Res. Appl, 2009.

Joint Research Center: In-Field Study2

Power Loss of 204 Field Aged c-Si Modules

Materials Choices Drive Real Differences in Lifetime Power Output

Materials Impact Module Lifetime & Performance

© DuPont

Relying on “Tier 1” Status Alone Does Not Guarantee Quality Modules

Financial Impact

• Cell corrosion • Polymer discoloration• Loss of insulation (unsafe for use) • Power degradation: -1.4%/yr

compounded vs. expected -0.5%/yr

Module : 125 W c-Si Module from Tier 1, “Bankable” Module MakerManufactured in 1998 with PET backsheets

Module : 125 W c-Si Module from Tier 1, “Bankable” Module MakerManufactured in 1998 with PET backsheets

106

~10% Reduction in Energy Value over life of project =

~$500,000 in Present Value

*Financials projected with System Adviser Model from NREL, Nominal Values ShownAssumptions: 1MW System, 12c/kWh flat sell rate, 8% Discount Rate, 2.5% Inflation

Degradation Issues

0

100

200

300

400

500

600

700

800

900

1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0

Ener

gy V

alue

(US$

000

's)

Years

Lifetime Energy Value Reduction ~10% or US$500,000 in Present Value

(1MW System @ 12¢/kWh*)

Lifetime Energy Value Reduction ~10% or US$500,000 in Present Value

(1MW System @ 12¢/kWh*)

© DuPont

1. Efficiency 2. Lifetime 3. Cost

Industry roadmap to 20+% c-Si cells,

enabled bynew materials

Robust materials enabling >25 year

module lifetimes with high performance

Lower cost, light- weight polymers to replace glass and

metals

© DuPont

Metal & Glass Replacement Reduces Both Weight and Total Installed Cost

Conventional New Design

Module Front Glass Fluoropolymer film

Module Frame Aluminum Polymer composite

Racking System Aluminum or Steel Polymer composite

Number of Parts Dozens 3

Installed Cost Standard 25% reduction

System Weight Standard > 50% reduction

Source: DuPont

© DuPont

Dozens of Materials Innovations in Development

Lifetime

Cost

EfficiencyN-type silicon wafers

Improved cell metallization Higher aspect ratio metallizationImproved anti-reflective coatings

Textured tabbing ribbonsImproved transparent conductive oxides

Better reflector films Higher blue light transparent materialsMore temperature resistant substrates

Thermally conductive substrates

Improved encapsulantsImproved anti-soiling/fouling coatings

More durable backsheetsBetter edge sealing

Higher reliability invertersThermally conductive substrates

MicroinvertersFlexible moisture barriers

More durable interconnects

Thinner Si wafersUpgraded metallurgical grade silicon

Faster lamination cycle timeSimpler mounting & racking systems

Lower moisture sensitivity encapsulantsThinner encapsulant filmsThinner backsheet films

New backsheet constructions Lighter weight materials

>20% by2012

30+ yearsby 2015

$2/WpInstalledby 2015

LCOE(US ¢/kWh)

LCOE(US ¢/kWh)

2010 2015 14 - 23 7 - 12 2010 2015 14 - 23 7 - 12

Source: DuPont

© DuPont

Summary

• Reduce PV LCOE by 50% to achieve broad-based grid parity

• Materials improvements deliver improved efficiency, lifetime performance and cost

• Clear roadmap to grid parity…driven by materials innovations

• Understanding material choices and specifications is critical to delivering your targeted project returns

For More Information on PV Materials:photovoltaics.dupont.com

© DuPont

© DuPont

Backsheet Type Has Significant Impact on Module Power Degradation

Materials Choices Drive Real Differences in Lifetime Power Outputand are Seldom Reflected in Financial Models Used by Banks & Developers

1: Ross, R. G., Jr. and Smokler, M. I. (1986) Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final report. Volume VI: Engineering sciences and reliability. JPL Publication, 86-31, volume VI. NASA , Springfield, VA2: Joint Research Centre (JRC), The Results of Performance Measurements of Field-aged c-Si Photovoltaic Modules, Prog. PV: Res. Appl, 2009.

• Standard Reliable Module Design

• Key Safety Standards

• Functional and Reliability Requirements

All modules approved in the final specification contained Tedlar®

0

10

20

30

40

50

60

70

80

Glass Plastic Polyester,Al

Silicone Tedlar®,Al

Tedlar®

Joint Research Center: In-Field Study2

Power Loss of 204 Field Aged c-Si Modules (19-23 years outdoor exposure)

Perc

ent P

ower

Los

s (%

)Consistent low power loss of TPT

TM

backsheet in PV modules over >20 years

Backsheet Type

JPL: Module Performance Study1