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At least 235 records · Page 13

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DOE OSTI2024

PV Performance Modeling and Stakeholder Engagement (Final Technical Report)

This core capability project’s objective is to increase the value of photovoltaic (PV) performance models by improving their functionality, demonstrating, and quantifying their validity, and offering a wide range of stakeholder engagement opportunities. In FY22-24, we developed new and improved modeling algorithms and functions to represent PV performance more accurately in a variety of environments and conditions. The “Model parameter toolkit” was developed and includes functions to translate between different module temperature models, incidence angle modifier models, and single-diode models. A new modeling capability named “PV Atlas” was also developed leveraging Sandia’s High Performance Computing resources. This capability allows us to investigate several questions and provide climate-specific best practices and geographic data files; all these are hosted on an interactive website on Sandia’s GitHub and can be used for training, system optimization, or to provide best practices for uncertainty reduction. For model validation, we published high-quality PV performance, and weather data; these data are well documented, filtered, and processed for quality and include examples on how to run PV simulations. We also developed well documented, standardized methods for validating PV models and ran independent model validation and 2 blind modeling intercomparisons engaging with 49 organizations from 17 countries. We co-led and contributed to a growing, well documented and maintained suite of open-source functions for PV modeling (i.e., the pvlib-python) and we outreached to the PV modeling stakeholders via the PVPMC workshops and web resources. In addition, this project supported US representation and leadership for the International Energy Agency (IEA) PVPS Task 13; specifically, members of our team led and supported 3 subtasks on: 1) Best practices for the optimization of bifacial photovoltaic tracking, 2) Extreme weather events and their multiple impact on PV power plants: Risks, failure mechanisms and mitigation strategies, and 3) Best practice guidelines for the use of economic and technical Key Performance Indicators (KPIs). This project resulted in the publications of 14 peer reviewed journal papers, 37 conference presentations, 6 SAND reports, 5 public datasets and 6 new webpages on the PVPMC website. It supported the release of 13 pvlib-python versions where 28 enhancements were from this PV Performance Modeling project. We co-organized 5 PVPMC workshops in FY22-24 with the participation of 214 unique institutions and around 700 participants. The PVPMC website was redesigned, and its reliability was improved; it receives over 50,000 visitors/year from 202 unique countries.

14 SOLAR ENERGY↗

NASA NTRS1985

Photovoltaic array performance and life-cycle cost simulation using new software tools

The three computer models, SAMICS, PVARRAY, and LCP can be used together as a single analytical tool to compare the lifetime economic value of a photovoltaic (PV) array. This evaluation can be used to compare various module and array configurations and the performance characteristics of different module manufacturing technologies.

Daniel, R. E.↗

DOE OSTI2024

Assessment of Accelerated Stress Testing Data for Silicon Photovoltaics Using Tensor Decomposition Methods

The photovoltaic (PV) industry is simultaneously targeting long warranties and new materials/designs for high-energy-yield modules, requiring an advanced methodology to forecast long-term durability of products with un-proven materials combinations. Extended, sequential, and combined stress testing methods are gaining popularity for assessing durability of PV modules/materials beyond the early-stage mortalities. Importantly, multiple degradation mechanisms can proceed simultaneously, and their separate contributions to the overall power loss should ideally be quantified. This work examines the use of data-driven tools towards developing a strategy for faster learning cycles in accelerated stress testing.

accelerated stress testing↗

DOE OSTI2025

In‐Scribe Silane Bonding for Mechanical Reinforcement of Perovskite Photovoltaic Modules

Despite the extraordinary rise in power conversion efficiency over the last decade, metal halide perovskite (MHP) photovoltaics remain more mechanically fragile than other PV technologies. In this work, the scribe area, created by the monolithic interconnection of thin-film solar cells, is used to extrinsically reinforce the mechanical robustness of packaged MHP solar modules. In contrast to the epoxy-based chemistries often leveraged in the MHP literature, silane-grafted polyolefin encapsulants are designed to form strong covalent bonds to oxide surfaces, specifically to glass and the transparent conductive oxide at the base of the scribe line. Pseudo-modules encapsulated with silane-grafted polyolefin are measured with more than an order-of-magnitude enhancement infracture energy from 0.27 ± 0.01 J·m −2 (no scribes) to 5.97 ± 0.42 J·m −2 (scribes perpendicular to delamination directioncovering ≈2.2% of the module area). The silane-grafted polyolefin retains strong adhesion even after undergoing an accelerated IEC 61215 thermal cycling test consisting of 250 cycles. We find that the in-scribe bonding allows perovskite modules to have adhesion strength comparable to commercial c-Si and CdTe technologies with only 5% reduction in the active module area. This manufacturing-compatible approach offers a practical solution to address the mechanical integrity challenges in MHP solar modules, regardless of cell architecture.

14 SOLAR ENERGY↗

DOE OSTI2025

Open data sets for assessing photovoltaic system reliability

Photovoltaic (PV) systems have become a cornerstone of renewable energy strategies, particularly due to the significant reduction in solar power costs over the past decade. However, the long-term reliability of PV installations presents a persistent challenge, requiring the development of advanced monitoring and predictive maintenance strategies. A wide range of data types is used to evaluate the health of PV systems, including environmental conditions, electrical performance, and inspection imagery. These data enable methodologies such as machine learning (ML) models for lifetime prediction and computer vision techniques for defect detection. However, the acquisition of high-quality and comprehensive data is difficult, particularly in terms of long-term consistency and data variety. Publicly available data sets serve as valuable resources for addressing these challenges, but they often suffer from fragmentation and are difficult to access. This paper presents a comprehensive review of existing open-source data sets related to PV degradation, analyzing their features, functionalities, and potential applications. We categorize these data sets based on the specific aspects of PV system information they cover, such as environmental conditions, operational monitoring, image inspection and module materials, and propose relevant tools and ML models for processing them. In addition, we propose practices for future data collection and usage, while also discussing potential directions in data-driven research. Our aim is to enhance data utilization and publication among researchers and industry professionals, promoting a deeper understanding of the role of data in enhancing the performance and durability of PV systems.

14 SOLAR ENERGY↗

DOE OSTI2024

PV Degradation Tools [SWR-20-71]

This open-source tool functions for calculating degradation of photovoltaic modules. For example, functions to calculate front and rear relative Humidity, as well as Acceleration Factors. A degradation calculation function is also being developed, considering humidity and spectral irradiances models.

Holsapple, Derek↗

DOE OSTI2024

Encapsulation Materials Tailored to Perovskite Photovoltaics

The work combines NREL as the world leader in perovskite and polymeric materials, and teams them up with The Dow Chemical Company, the world leader in commercial production of PV encapsulation materials. The team will design and evaluate encapsulation materials that are tailored to perovskite photovoltaics. Demonstration of polyolefin-based encapsulants for perovskite PV will be impactful for a number of reasons: 1) There is no clear-cut choice for encapsulation for perovskite PV to date. 2) There is high synthetic control of the material properties for future perovskite module designs. 3) Among the candidate materials, they have the highest barrier properties, 4) Polyolefins are the most prevalent (>20 million metric tons consumed in the US alone) and inexpensive (<1.5 $USD/kg) polymers used worldwide. 5) They are recyclable and may play a role in future of circular PV materials. 6) They are manufactured domestically. The work also highlights careful design of perovskite transport layer materials for surviving vacuum encapsulation.

14 SOLAR ENERGY↗

NASA NTRS1983

Photovoltaic power - An important new energy option

A review of photovoltaic (PV) power technology is presented with an emphasis of PV as an economical and technically feasible alternative source of energy. The successful completion of the development and transfer of emerging low-cost technologies into a fully commercialized status are identified as the means to the realization of this option's full potential. The DOE National Photovoltaics Program, a significant sponsor of PV R&D, expects both flat-plate and concentrator collectors to meet established cost targets. Citing the DOE large flat-plate grid-connected system project of the Sacramento Municipal Utility District, current technology modules priced at near $5/Wp (1983 dollars) are steadily reducing costs. A recent DOE study suggests that PV-generated electricity produced at a 30-year levelized cost of 15 cents per kWh would represent a viable energy supply alternative for the nation.

Ferber, R. R.↗

DOE OSTI2024

Reducing Thermal Degradation of Perovskite Solar Cells during Vacuum Lamination by Internal Diffusion Barriers

Current photovoltaic (PV) panels typically contain interconnected solar cells that are vacuum laminated with a polymer encapsulant between two pieces of glass or glass with a polymer backsheet. This packaging approach is ubiquitous in conventional photovoltaic technologies such as silicon and thinfilm solar modules, contributing to thermal management, mechanical reinforcement, and environmental protection to enable the long lifetimes necessary to become financially acceptable. Commercial vacuum lamination processes typically occur at 150 °C to ensure cross-linking and/or glass bonding of the encapsulant to the glass and PV cells. Perovskite solar cells (PSCs) have emerged as a promising next-generation PV technology that is known to degrade under thermal stresses, especially at temperatures above 100 °C. In this study, we determine degradation modes during lamination and engineer internal diffusion barriers within the PSC to withstand the harsh thermal conditions of vacuum lamination. PSCs with self-assembled monolayers at the ITO interface and SnO X layers deposited by atomic layer deposition at the electron extraction side of the device endured vacuum lamination at conditions typical of commercial PV processes (150 °C) without degradation. This work demonstrates that perovskite PV can be integrated into the existing module lamination process, enabling future single- and multijunction modules utilizing perovskite absorbers.

14 SOLAR ENERGY↗

DOE OSTI2026

Microstructure and Composition of Passivating Interfaces in Silicon Heterojunction Solar Modules Weathered in Different Climates

Sanyo/Panasonic patented silicon heterojunction with intrinsic thin layer (HIT) solar cells in the 1990's, which demonstrated world record photovoltaic (PV) efficiency around 2014 and inspired the newer generations of silicon heterojunction technology (SHJ) as well as the current world record back-contact PV cell designs. The high-quality passivation strategy, utilizing ultra-thin layers of hydrogenated amorphous silicon (a-Si:H), leads to high voltages and long carrier lifetimes, but these qualities may degrade over time as the modules operate outdoors. Here, we investigate local microstructure and composition at the interface layers of cells from HIT modules weathered in a hot, humid climate (Florida, USA) and temperate climate (Colorado, USA) for 10 years. We employ a comprehensive set of high-resolution electron microscopy imaging and spectroscopy to directly resolve structure and composition in these cells down to the nanoscale. We show features such as alignment of the In2O3 transparent conducting oxide and a-Si:H layers on the textured c-Si facets, interfacial oxidation at the a-Si:H/c-Si and In2O3/a-Si:H interfaces, and twinned c-Si resulting from epitaxial growth into the a-Si:H layer. Our results raise potential degradation mechanisms in these outdoor-weathered modules, but the root cause of electrical loss remains uncertain due to the very small changes in aged samples. This study shows that many atomic scale features at the In2O3/a-Si:H/c-Si interfaces are surprisingly robust, and the electrical losses with aging may either be attributed to other pathways or be very sensitive to the subtle chemical and microstructural features observed here.

14 SOLAR ENERGY↗

NASA NTRS1982

Research possibilities? No! Needs for research to make PV solar energy utilization broadly competitive

The historical progression of efficiency improvements, cost reductions, and performance improvements in modules and photovoltaic systems are described. The potential for future improvements in photovoltaic device efficiencies and cost reductions continues as device concepts, designs, processes, and automated production capabilities mature. Additional step-function improvements can be made as today's simpler devices are replaced by more sophisticated devices.

Wolf, M.↗

NASA NTRS1984

Flat-plate module efficiency versus cost tradeoffs

The Five Year Research Plan energy cost methodology and in depth analyses based on the extensive data that are relevant to PV systems are used to facilitate the accomplishment of the $0.15/kWh energy cost goal. An equation is given for the five year energy cost methodology. The allocation guidelines are designed to be consistent with flat solar array (FSA) milestones for module cost, module efficiency, and the programmatic goal for energy cost. They are research targets that appear to be achievable, given prior accomplishments and planned activities in the areas of low cost silicon purification, low cost sheet material, high efficiency cell processing, low cost, long life encapsulants, and automated fabrication method. Extensive sensitivity analysis work has been performed that shows that these guidelines represent an efficient way to meet the intent of the DOE program.

Aster, R. W.↗

DOE OSTI2024

Low-cost Manufacturing of Semitransparent CdTe PV for Building Integration

Solar has been demonstrated to be a robust renewable energy source, constituting a significant portion of the United States’ renewable energy portfolio. Despite its growth across residential, commercial, and utility sectors over the past decades, it remains a small fraction of the overall energy infrastructure. Challenges persist in fully harnessing solar power to meet the nation's escalating energy demands. Among these challenges lies the hurdle of efficiently distributing large quantities of solar-generated electricity to densely populated regions with the highest energy needs and costs. Traditional utility-scale arrays demand extensive land, a luxury often unavailable in metropolitan areas. Consequently, installations must be situated at a distance, necessitating additional infrastructure for electricity transmission to service areas. While metropolitan landscapes lack sprawling open spaces suitable for conventional utility-scale solar deployment, they offer a different resource: windows. Semitransparent photovoltaic window technology has the potential to not only bolster the grid's energy capacity, but to also provide HVAC and economic advantages to building owners. However, commercial availability of building-integrated photovoltaic windows remains limited. Silicon based photovoltaics currently dominate the solar market but adapting them for use in windows poses a variety of engineering and economic challenges such as relatively low power density, high costs associated with custom manufacturing, and aesthetic considerations. Addressing these challenges, this project explored the use of laser ablation patterning to manufacture cost-effective, high-efficiency, semitransparent Cadmium Telluride photovoltaic modules. Results showcased the potential of this methodology in developing photovoltaic windows and other innovative semitransparent PV applications. The ablation manufacturing technique demonstrated great versatility in achieving different patterns and levels of visible light transmission, and the power loss due to ablation was nearly directly proportional to the amount of material removed. Furthermore, the manufacturing process for Cadmium Telluride modules already has established advantages in material and energy efficiency, and the conversion of a standard submodule to semitransparent essentially requires a single additional process step, ensuring scalability. It is important to note that during this work, Toledo Solar experienced substantial organizational upheaval stemming from a lawsuit with First Solar. An external investigation led the board of directors to remove and replace the previous management team, and several other members of the staff elected to depart as well, including the then acting Principle Investigator on this project. The remaining Toledo Solar team attempted to recover from the disruption and deliver on the remaining tasks, but upon its own review, the Department of Energy ruled the project in default and terminated the contract in December 2023.

14 SOLAR ENERGY↗

DOE OSTI2025

Assessing the Impacts of Extreme Weather Events on Photovoltaic Installations Using Remote Sensing Imagery

In this study, we analyze poststorm satellite imagery to assess solar photovoltaic (PV) damage for over 11,300 systems following a catastrophic hailstorm in Austin, TX, in September 2023, which produced softball‐sized hail and for over 1500 systems across Puerto Rico and the US Virgin Islands after Hurricanes Irma and Maria in September 2017. Findings show that approximately 5.5% of identified PV sites were damaged in the hailstorm and approximately 17% of PV installations were damaged after the hurricanes. A weak correlation between hurricane wind gust speed and percent site damage was determined, with installation practices playing a heavy role in site resilience. Additionally, we show that newer module vintages are more susceptible to hail damage than older modules, possibly due to a convergence of larger size modules, decreased frame dimensions, and decreased front glass thickness but more research is needed. For hail sizes of 60 mm or greater, consistent hail damage is sustained by PV installations, regardless of system configuration.

14 SOLAR ENERGY↗

NASA NTRS1984

Topics in electrochemical degradation of photovoltaic modules

Electrochemical degradation of photovoltaic modules was examined. It is found that the extent of electrochemical damage is dependent on the integrated leakage current. The PV electrochemical degradation mechanisms in the two polarities are different: (1) degradation rates in the two polarities are of the same order of magnitude; (2) center tapped grounded arrays are a preferred system configuration to minimize electrochemical degradation. The use of thicker pottant layers and polymer substrate films to reduce equilibrium leakage current values is suggested. A metallized substrate layer, if used, should be isolated from the pottant and the frame by polyester layers, and EVA modules appear to be consistent with 30 year life allocation levels for electrochemical damage. Temperature acceleration factors are well behaved and moderately well understood; humidity acceleration factors vary radically with module construction and materials and require additional research.

Mon, G. R.↗

DOE OSTI2024

Prioritizing circular economy strategies for sustainable PV deployment at the TW scale

Global decarbonization requires an unprecedented scale-up of photovoltaic (PV) manufacturing and deployment. The material demand and eventual end of life management associated with multi-TW scale deployment poses many challenges. Circular Economy (CE) and it's associated R-Actions (Reduce, Reuse, Recycle) have been proposed to mitigate end of life management and material sourcing concerns. However, CE metrics typically focus on a single product and only consider mass, excluding energy flows. This work leverages the PV in Circular Economy (PV ICE) tool to quantify the deployment, mass, and energy impacts of R-Actions and proposed sustainable PV designs in the context of achieving energy transition deployment goals (75 TW in 2050). 13 module scenarios are established and evaluated across 6 capacity, mass and energy metrics to identify tradeoffs and priorities. We find that increasing module efficiency can reduce near-term material demands up to 30% and improve energy metrics by up to 9%. Material circularity (recycling) can minimize lifecycle wastes and reduce material demands at the cost of higher energy demands. Increasing module lifetime, including reliability improvements and reuse strategies, is effective at reducing both material (>10%) and energy demands (24%). Uniquely, lifetime improvements maximize benefits and minimize the harms across all six metrics while achieving multi-TW scale deployment.

Photovoltaics↗

NASA NTRS1995

Determination of tire cross-sectional geometric characteristics from a digitally scanned image

A semi-automated procedure is described for the accurate determination of geometrical characteristics using a scanned image of the tire cross-section. The procedure can be useful for cases when CAD drawings are not available or when a description of the actual cured tire is desired. Curves representing the perimeter of the tire cross-section are determined by an edge tracing scheme, and the plyline and cord-end positions are determined by locations of color intensities. The procedure provides an accurate description of the perimeter of the tire cross-section and the locations of plylines and cord-ends. The position, normals, and curvatures of the cross-sectional surface are included in this description. The locations of the plylines provide the necessary information for determining the ply thicknesses and relative position to a reference surface. Finally, the locations of the cord-ends provide a means to calculate the cord-ends per inch (epi). Menu driven software has been developed to facilitate the procedure using the commercial code, PV-Wave by Visual Numerics, Inc., to display the images. From a single user interface, separate modules are executed for image enhancement, curve fitting the edge trace of the cross-sectional perimeter, and determining the plyline and cord-end locations. The code can run on SUN or SGI workstations and requires the use of a mouse to specify options or identify items on the scanned image.

Danielson, Kent T.↗

DOE OSTI2024

pvplr-python: Python package implementation of PVplr for Performance Loss Rate (PLR) analysis

Due to software fragmentation, PV system modeling teams can be limited to language specific packages, preventing cross-sectional analysis of different modeling techniques and workflows. To this end, PVplr, a popular PV performance modeling R software package, has been ported to the Python programming language. To verify and test the robustness of the port, NSRDB data has been used to simulated PV installations at native resolution (~2 million Sites), with a variety of degradation rates, degradation patterns, and modules. Performance Ratios were calculated using the ported functions from pvplr-python and compared against Rdtools YoY values. Due to the complicated nature of degradation, a new metric has been proposed to quantify the performance loss of a system. The cumulative production loss, is the total amount of energy lost due to the degrading performance of the system. Cumulative production loss alleviates the problems with fitting linear functions to non-linear degradation. Cumulative Production loss was shown to better estimate the total lost revenue for non-linear degradation patterns. $XbX + UTC$ was found to most accurately predict the total lost revenue in simulated systems.

Kumar, Suraj↗