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At least 361 records · Page 20

Perspectives of Open-Air Processing to Enable Perovskite Solar Cell Manufacturing

We report high throughput open-air processing techniques for the scalable production of all device and barrier layers for perovskite photovoltaics (PV). This work discusses and resolves some of the most formidable barriers to module-level scaling that the perovskite community has been facing. Our advanced technoeconomic manufacturing analysis indicates that vacuum-based processes with high capital expenditures (CapEx) and low throughputs dominate the cost of production. Open-air fabrication methods offer low CapEx routes to manufacturing, but achieving reproducibility in ambient conditions with varying relative humidity has been a persistent challenge. The use of rapid processing methods with plasma curing to convert films from the solution-state enables reproducibility, moisture immunity, and the highest perovskite PV efficiency produced in open-air. These methods are readily translatable to in-line processing where layers are sequentially deposited without the need for lengthy post-annealing steps that reduce throughput and involve additional equipment. Significant progress is demonstrated in reduced manufacturing costs as perovskites contend as a commercially viable next-generation thin film PV technology.

14 SOLAR ENERGY↗

Technoeconomic Analysis of Dye Sensitized Solar Cells (DSSCs) with WS 2 /Carbon Composite as Counter Electrode Material

Exploration of clean and renewable energy materials is necessary due to the coming energy crisis and environmental problems. Solar energy is one of the favorable energy sources because of the continuous energy reservoir and its affluence. Silicon-based solar devices are expensive due to their complicated production process, which limits this technology for urban and other commercial applications. Among the third generation of solar cells, Dye-Sensitized Solar Cells (DSSCs) have attracted widespread attention as potential cost-effective alternatives to silicon-based solar cells. In this paper, the commercializing potential of the DSSCs is investigated. A module is introduced where the materials, equipment, and distribution of direct manufacturing costs are calculated. The manufacturing costs and the Levelized Cost of Energy (LCOE) of these DSSCs for a system lifetime of 25 years were determined to be USD 22.40 per m 2 and USD 0.0438 per kWh and the module price of this technology is USD 0.18 per W and the total installed system cost is USD 0.88 per W in Kansas which suggest that this PV technology could challenge other leading PV technologies.

14 SOLAR ENERGY↗

Reaching Grid Parity Using BP Solar Crystalline Silicon Technology: A Systems Class Application

The primary target market for this program was the residential and commercial PV markets, drawing on BP Solar's premium product and service offerings, brand and marketing strength, and unique routes to market. These two markets were chosen because: (1) in 2005 they represented more than 50% of the overall US PV market; (2) they are the two markets that will likely meet grid parity first; and (3) they are the two market segments in which product development can lead to the added value necessary to generate market growth before reaching grid parity. Federal investment in this program resulted in substantial progress toward the DOE TPP target, providing significant advancements in the following areas: (1) Lower component costs particularly the modules and inverters. (2) Increased availability and lower cost of silicon feedstock. (3) Product specifically developed for residential and commercial applications. (4) Reducing the cost of installation through optimization of the products. (5) Increased value of electricity in mid-term to drive volume increases, via the green grid technology. (6) Large scale manufacture of PV products in the US, generating increased US employment in manufacturing and installation. To achieve these goals BP Solar assembled a team that included suppliers of critical materials, automated equipment developers/manufacturers, inverter and other BOS manufacturers, a utility company, and University research groups. The program addressed all aspects of the crystalline silicon PV business from raw materials (particularly silicon feedstock) through installation of the system on the customers site. By involving the material and equipment vendors, we ensured that supplies of silicon feedstock and other PV specific materials like encapsulation materials (EVA and cover glass) will be available in the quantities required to meet the DOE goals of 5 to 10 GW of installed US PV by 2015 and at the prices necessary for PV systems to reach grid parity in 2015. This final technical report highlights the accomplishments of the BP Solar technical team from 2006 to the end of the project in February 2010. All the main contributors and team members are recognized for this accomplishment and their endeavors are recorded in the twelve main tasks described here.

14 SOLAR ENERGY↗

Industry Facing PV Degradation Prediction Tool and Database to Enable a 50-Year Life Module

The Photovoltaic (PV) industry constantly aims for lower costs, higher-efficiency cells, and improved module designs. These trends lead to using new materials, designs, and manufacturing processes, resulting in a continually changing technological landscape. These changes can potentially introduce new, unknown degradation mechanisms and failure modes that are difficult to diagnose, analyze, test, and model. This introduces uncertainty into the expected lifetime of PV modules of 25 years. Furthermore, research efforts aim for up to 50 years of service life while keeping performance degradation at a minimum for decades of outdoor weathering - putting additional pressure on improving the accuracy of long-term durability and reliability assessments. Here there is a need to organize the existing degradation data into an accessible format and to provide industry relevant tools for extrapolation from laboratory to field conditions. Because the core of this type of analysis involves calculations that are complicated but ubiquitous for many degradation processes, an enhanced predictive modeling framework will facilitate the analysis to help researchers keep up with the rapid pace of technological changes. In this work, we present an online tool that can be used to search for and analyze degradation information and extrapolate PV module performance and durability to field exposure. A graphical user interface will aid in the understanding of the results. The prediction tool will be built modular and published as open source, enabling users to expand on the existing framework. We use an integration pipeline approach that allows us to leverage weather data from the National Solar Radiation Database to perform geospatial degradation analysis in the US and worldwide. Our repository will contain various degradation models and material parameters suitable for the reliability and durability assessment of materials and components deployed outdoors. We hope to become a repository that can be used for weathering and degradation analysis for various applications beyond the PV industry.

degradation↗

PVDeg: Development of a Streamlined Tool for PV Degradation Modeling

The photovoltaic (PV) industry constantly aims for lower costs, higher-efficiency cells, and improved module designs. These trends lead to using new materials, designs, and manufacturing processes, resulting in a continually changing technological landscape. These changes can potentially introduce new, unknown degradation mechanisms and failure modes that are difficult to diagnose, analyze, test, and model. This introduces uncertainty into the expected lifetime of PV modules of 25 to 50 years. research efforts aim to achieve this while keeping performance degradation at a minimum for decades. This puts considerable pressure on improving the accuracy of long-term durability and reliability assessments. There is a need to organize the existing degradation data into an accessible format and to provide industry relevant tools for extrapolation from laboratory to field conditions. Because the core of this type of analysis involves calculations that are complicated but ubiquitous for many degradation processes, an enhanced predictive modeling framework will facilitate the analysis to help researchers keep up with the rapid pace of technological changes. In this work, we present an online tool that can be used to search for and analyze degradation information and extrapolate PV module performance and durability to field exposure. The tool will simplify many of the routine computational operations that are common to many degradation studies. The prediction tool will be built modular and published as open source, enabling users to expand on the existing framework. This repository will contain various degradation models and material parameters suitable for the reliability and durability assessment of materials and components deployed outdoors.

degradation↗

Li-Ion Battery Thermal Characterization for Thermal Management Design

Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing the thermal profile of battery cells, are crucial for balancing the trade-offs between battery performance and lifetime. Designing such systems requires accounting for the multitude of heat sources within battery cells and packs. This paper provides a summary of heat generation characterizations observed in several commercial Li-ion battery cells using isothermal battery calorimetry. The primary focus is on assessing the impact of temperatures, C-rates, and formation cycles. Moreover, a module-level characterization demonstrated the significant additional heat generated by module interconnects. Characterizing heat signatures at each level helps inform manufacturing at the design, production, and characterization phases that might otherwise go unaccounted for at the full pack level. Further testing of a 5 kWh battery pack revealed that a considerable temperature non-uniformity may arise due to inefficient cooling arrangements. To mitigate this type of challenge, a combined thermal characterization and multi-domain modeling approach is proposed, offering a solution without the need for constructing a costly module prototype.

25 ENERGY STORAGE↗

Development of Scanning Near-Field Ultrasound Holography as an Add-On Module for AFM systems

The project aimed to develop a standalone module for Atomic Force Microscope systems that the biological and environmental research community could use to image and quantify to a greater extent the interactions between nanoparticles and cells. If successful, it would enable the thousands of biological and environmental researchers with access to atomic force microscopes to perform scanning near field ultrasound holography to image nanoparticle interactions with cells. Over the course of this effort, grantees were able to develop a standalone module capable of performing scanning near field ultrasound holography on a variety of commercial systems. The add-on module was tested on systems from 3 of the major Atomic Force Microscope manufacturers (Veeco, JEOL and Park Systems). Furthermore, the investigators believe that the hardware developed will be capable of performing the technique on any AFM with standard signal access modules. The discrete components previously used to perform the SNFUH technique could cost upward of $\$$40,000. Beyond the cost issue, the components are bulky and cumbersome to work with because of the wiring needed between each of the components when implementing the technique. NanoSonix was able to dramatically reduce both the cost and complexity of implementing SNFUH, developing two functional versions of an add-on module (A&B) using National Instruments hardware as put forth in the proposal. More significantly, NanoSonix exceeded the aims of the proposal by developing completely custom electronics that should enable an almost order of magnitude cost reduction while improving the capability versus the discrete componentry. Because potential biological systems are so complex, biological applications of the technique are very diverse and require very distinct domain knowledge. This inhibits the utilization widespread adoption and penetration of new metrology techniques. Northwestern University and NanoSonix has made it both possible and practical for widespread adoption of the technique through the development of a standalone system with order of magnitude cost reduction and significant reduction in complexity. NanoSonix believes that it can produce the add-on modules and make them available to the academic research community at a price point below $\$$10,000, thereby enabling the biological research community to hardness the over 30,000 AFMs in existence around the world today, approximately 18,000 of which reside in the United States at a very modest incremental cost. Finally, we were able to implement a multi-frequency function generator and simultaneous multi-frequency lock-in amplifier with an internal reference frequency (which significantly simplifies the experimental setup) that it believes could lay the foundation for future non-destructive nanoscale 3-D tomography of buried and embedded sub-structures in cells and tissues. To date, we has been unable to find multiple frequency combinations which yield sufficiently strong mixing at the tip-sample interaction, but believes it is conceptually possible and doing so would enable the use of frequency dependent phase shift to better characterize the subsurface structures. Taken together, we believes that this work has materially advanced the prospects of enabling researchers to develop time-resolved cellular uptake of the nanoparticles used for drug delivery, cancer therapies, gene delivery and gene silencing and to assess cellular uptake of nanoparticles for environmental monitoring/remediation/impact.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Nonfullerene Acceptor Featuring Unique Self‐Regulation Effect for Organic Solar Cells with 19 % Efficiency

Abstract The blend nanomorphology of electron‐donor (D) and ‐acceptor (A) materials is of vital importance to achieving highly efficient organic solar cells. Exogenous additives especially aromatic additives are always needed to further optimize the nanomorphology of blend films, which is hardly compatible with industrial manufacture. Herein, we proposed a unique approach to meticulously modulate the aggregation behavior of NFAs in both crystal and thin film nanomorphology via self‐regulation effect. Nonfullerene acceptor Z9 was designed and synthesized by tethering phenyl groups on the inner side chains of the Y6 backbone. Compared with Y6, the tethered phenyl groups participated in the molecular aggregation via the π–π stacking of phenyl‐phenyl and phenyl‐2‐(5,6‐difluoro‐3‐oxo‐2,3‐dihydro‐1H‐inden‐1‐ylidene)malononitrile (IC‐2F) groups, which induced 3D charge transport with phenyl‐mediated super‐exchange electron coupling. Moreover, ordered molecular packing with suitable phase separation was observed in Z9‐based blend films. High power conversion efficiencies (PCEs) of 19.0 % (certified PCE of 18.6 %) for Z9‐based devices were achieved without additives, indicating the great potential of the self‐regulation strategy in NFA design.

Chemistry↗

Field-Array Benchmark of Commercial Bifacial PV Technologies with Publicly Available Data

We present results for a 75-kW field array deployed with rows of 5 different commercially available bifacial technologies. Four PERC (multi and mono) and 1 Silicon Heterojunction manufacturers are represented. Reference strings of equivalent monofacial PV modules are also installed in the 10-row field. High accuracy string-level DC monitoring and module-level measurements have been recorded for six months. Analysis indicates performance within expectation, with a cumulative model mean error within +/- 2% for both bifacial and monofacial models and cumulative bifacial energy gain between 6-9%. A custom-module to measure shading loss from the torque-tube was installed. One month data shows up to 6% irradiance non-uniformity. A fixed-tilt test-site with 3 years of bifacial data is also presented, with a bifacial gain of 3%.

41 EE - Solar Energy Technologies Office (EE-4S)↗

Development of Production-Intent Plug-In Hybrid Vehicle Using Advanced Lithium-Ion Battery Packs with Deployment to a Demonstration Fleet

The primary goal of this project was to speed the development of one of the first commercially available, OEM-produced plug-in hybrid electric vehicles (PHEV). The performance of the PHEV was expected to double the fuel economy of the conventional hybrid version. This vehicle program incorporated a number of advanced technologies, including advanced lithium-ion battery packs and an E85-capable flex-fuel engine. The project developed, fully integrated, and validated plug-in specific systems and controls by using GM’s Global Vehicle Development Process (GVDP) for production vehicles. Engineering Development related activities included the build of mule vehicles and integration vehicles for Phases I & II of the project. Performance data for these vehicles was shared with the U.S. Department of Energy (DOE). The deployment of many of these vehicles was restricted to internal use at GM sites or restricted to assigned GM drivers. Phase III of the project captured the first half or Alpha phase of the Engineering tasks for the development of a new thermal management design for a second generation battery module. The project spanned five years. It included six on-site technical reviews with representatives from the DOE. One unique aspect of the GM/DOE collaborative project was the involvement of the DOE throughout the OEM vehicle development process. The DOE gained an understanding of how an OEM develops vehicle efficiency and FE performance, while balancing many other vehicle performance attributes to provide customers well balanced and fuel efficient vehicles that are exciting to drive. Many vehicle content and performance trade-offs were encountered throughout the vehicle development process to achieve product cost and performance targets for both the OEM and end customer. The project team completed two sets of PHEV development vehicles with fully integrated PHEV systems. Over 50 development vehicles were built and operated for over 180,000 development miles. The team also completed four GM engineering development Buy-Off rides/milestones. The project included numerous engineering vehicle and systems development trips including extreme hot, cold and altitude exposure. The final fuel economy performance demonstrated met the objectives of the PHEV collaborative GM/DOE project. Charge depletion fuel economy of twice that of the non-PHEV model was demonstrated. The project team also designed, developed and tested a high voltage battery module concept that appears to be feasible from a manufacturability, cost and performance standpoint. The project provided important product development and knowledge as well as technological learnings and advancements that include multiple U.S. patent applications.

25 ENERGY STORAGE↗

Ultimate Bifacial Showdown: 75kW Field Results

This work presents one year results for a side-by-side comparison of 5 different bifacial technologies, deployed in a 75-kW single-axis tracked field at Golden, CO. Four PERC (multi and mono) and 1 Silicon Heterojunction manufacturers are represented. Reference strings of equivalent monofacial PV modules are also installed for a direct technology comparison and calculation of bifacial gain. Analysis indicates performance within expectation, with a cumulative model mean error within +/- 2% for both bifacial and monofacial models and cumulative bifacial energy gain between 6-9%. High accuracy string-level DC monitoring and module-level measurements are also presented, showing effects of snow and edge effects in the order of +/- 3% for non-uniform irradiance across the row. Data from a custom-module to measure shading loss from the torque-tube is installed, showing up to 6% irradiance non-uniformity for the month of January.

bifacial field validation↗

Unfounded concerns about photovoltaic module toxicity and waste are slowing decarbonization

Unsubstantiated claims that fuel growing public concern over the toxicity of photovoltaic modules and their waste are slowing their deployment. Clarifying these issues will help to facilitate the decarbonization that our world depends on. Harnessing the potential of photovoltaic (PV) electricity generation is a key part of the transition to less carbon-intensive energy sources. The most recent energy production forecasts call for a massive 75 TW of global PV capacity by 2050 to have a chance of limiting global temperature rise to 1.5 °C and minimizing the impacts of climate change. This is more than a tenfold increase in the current manufacturing and deployment rate in less than 15 years. PV modules are new to many people, so increasing PV deployment has led to growing concerns about the quantity of waste that may arise from decommissioning them (if they are not recycled), and their potential to leach toxic metals. In conclusion, debunking misinformation about PV modules and PV module waste is the first step in addressing these concerns that are unnecessarily slowing PV deployment.

14 SOLAR ENERGY↗

Flow dynamics and heat transfer in simplified battery energy storage systems with heated battery modules

Large-scale energy storage systems (ESSs) composed of batteries show promise in addressing current energy challenges, but dissipation of generated heat is important. Here, this paper focuses on buoyant convective flows in simplified ESS battery racks. Natural convection is not generally the primary cooling strategy but can be important in abnormal scenarios where there is module overheat or potentially thermal runaway. We use computational fluid dynamics to investigate the flow dynamics and heat transfer mechanisms in a simplified parameterized rack design. Despite its simplicity, this configuration produces many of the relevant features expected in real ESSs without details of module geometry or hardware, allowing broad conclusions independent of manufacture-specific designs. We start by providing visualizations of the flowfield and measurements of entrainment, heat flux, and pressure. To characterize the dependence on the system parameters, we develop an integral-scale analysis of the average temperature equation to highlight the dominant source terms. We use results from this analysis to derive a steady network model composed of simple algebraic expressions to provide first-order predictions of entrainment through the rack. The network model leads to a linear scaling of the Reynolds number based on convective mass flux with respect to the Grashof number based on the heat source. We deduce empirical relationships that relate the heat exchanged between modules using a surface-averaged Nusselt number as a function of the local Reynolds and Rayleigh numbers. Lastly, we investigate how space between the modules and rack in the spanwise direction creates flow bypass, resulting in different flow pathways.

Battery thermal management↗

Development of an Air-Source Heat Pump Integrated with a Water Heating / Dehumidification Module

A residential-sized dual air-source integrated heat pump (AS-IHP) concept is under development in partnership between ORNL and a manufacturer. The concept design consists of a two-stage air-source heat pump (ASHP) coupled on the air distribution side with a separate novel water heating/dehumidification (WH/DH) module. The motivation for this unusual equipment combination is the forecast trend for home sensible loads to be reduced more than latent loads. Integration of water heating with a space dehumidification cycle addresses humidity control while performing double-duty. This approach can be applied to retrofit/upgrade applications as well as new construction. A WH/DH module capable of ~1.47 L/h water removal and ~2 kW water heating capacity was assembled by the manufacturer. A heat pump system model was used to guide the controls design; lab testing was conducted and used to calibrate the models. Performance maps were generated and used in a TRNSYS sub-hourly simulation to predict annual performance in a well-insulated house. Annual HVAC/WH energy savings of ~35% are predicted in cold and hot-humid U.S. climates compared to a minimum efficiency baseline.

dehumidification↗

The "PVLib" of Degradation: PVDeg

The Photovoltaic (PV) industry constantly aims for lower costs through higher-efficiency cells, improved module designs, and improvements in durability. This leads to the use of new materials, designs, and manufacturing processes, and not always with a sufficient amount of durability testing. To help drive down costs there is a desire to create modules that will last for up to 50 years of service life. To accomplish this, every degradation mode and mechanism must be identified and either eliminated or otherwise mitigated. This involves the extrapolation of laboratory results to the field conditions. There is a need to organize the existing degradation data into an accessible format and to provide industry relevant tools for extrapolation from laboratory to field conditions. While the basic equations used to model degradation are sometimes very simple, the full analysis involves calculations are cumbersome but ubiquitous for many degradation processes. A simplified, modeling framework to accomplish these repetitive processes will facilitate the analysis to help researchers keep up with the rapid pace of technological changes. In this talk, we will describe our progress creating the open-source tool PVDeg. This tool can be used to search for and analyze degradation information and extrapolate PV module performance and durability to field exposure. PVDeg simplifies many of the common foundational computational operations for obtaining meteorological data and using it to generate a model of the PV deployment. This prediction tool repository also contains various degradation models as well as a library of material parameters suitable for estimating the durability assessment of materials and components. We use an integration pipeline approach that allows us to leverage weather data from the National Solar Radiation Database, and other weather sources, to perform geospatial degradation analysis in the US and worldwide. We hope to become a repository that can be used for weathering and degradation analysis for various applications beyond the PV industry. During the talk, we will provide the PVPMC attendees the opportunity to interact with the tool via a Google Collab tutorial they can run on their phones or laptops.

durability↗

Diffraction-Based Optical Switching with MEMS

In this article, we are presenting an overview of MEMS-based (Micro-Electro-Mechanical System) optical switch technology starting from the reflective two-dimensional (2D) and three-dimensional (3D) MEMS implementations. To further increase the speed of the MEMS from these devices, the mirror size needs to be reduced. Small mirror size prevents efficient reflection but favors a diffraction-based approach. Two implementations have been demonstrated, one using the Texas Instruments DLP (Digital Light Processing), and the other an LCoS-based (Liquid Crystal on Silicon) SLM (Spatial Light Modulator). These switches demonstrated the benefit of diffraction, by independently achieving high speed, efficiency, and high number of ports. We also demonstrated for the first time that PSK (Phase Shift Keying) modulation format can be used with diffraction-based devices. To be truly effective in diffraction mode, the MEMS pixels should modulate the phase of the incident light. We are presenting our past and current efforts to manufacture a new type of MEMS where the pixels are moving in the vertical direction. The original structure is a 32 x 32 phase modulator array with high contrast grating pixels, and we are introducing a new sub-wavelength linear array capable of a 310 kHz modulation rate

36 MATERIALS SCIENCE↗

Flexible Thin-Film Silicon Solar Cells

High fuel costs, environmental concerns and issues of national energy security have brought increasing attention to a distributed generation program for electricity based on solar technology. Rooftop photovoltaic (PV) systems provide distributed generation since the power is consumed at the point of production, thus eliminating the need for costly additional transmission lines. However, most current photovoltaic modules are heavy and require a significant amount of labor and accessory hardware such as mounting frames for installation on rooftops. This makes rooftop systems impractical or cost prohibitive in many instances. Under this project, Xunlight has advanced its manufacturing process for the production of lightweight, flexible thin-film silicon based photovoltaic modules, and has enhanced the reliability and performance of Xunlight’s products. These modules are easily unrolled and adhered directly to standard commercial roofs without mounting structures or integrated directly into roofing membrane materials for the lowest possible installation costs on the market. Importantly, Xunlight has now established strategic alliances with roofing material manufacturers and other OEMs for the development of building integrated photovoltaic roofing and other PV-enabled products, and has deployed its products in a number of commercial installations with these business partners.

14 SOLAR ENERGY↗

Improving Solar PV Degradation Prediction Certainty: PREDICTS2 (Final Technical Report)

The rate and type of in-service PV performance degradation vary for different module designs, vintages, and operating climates. The current IEC 61215 module qualification testing standard can be used to identify design and manufacturing flaws that may lead to early life failures, but it was not intended to accurately predict degradation rates in the first 5 to 10 years of a PV plant’s lifetime, nor long-term performance, under varied operating conditions. Correlations between accelerated aging data and real-world degradation data are needed to better predict wear-out degradation in response to environmental stressors, such as elevated temperature, temperature cycling, moisture, wind load, and solar radiation. The PREDICTS2 project aged 36 pristine-condition ‘spare’ modules from a commercial PV power plant in the U.S. Southwest using the IEC 61215 and Qualification Plus (Qual Plus) testing standards. The study is unique in its ability to compare performance degradation data for fielded modules operating outdoors for 6 years in a commercial plant environmental with degradation data for modules of the same make, model and vintage that have been aged artificially in an indoor laboratory. Changes in individual module current-voltage (I-V) curve data were measured before and after the artificial aging process and compared to I-V curve data for the fielded modules. This project advanced the industry’s understanding of how environmental stressors affect performance degradation and established relationships between degradation mechanisms and changes to module electrical parameters and power loss. Improved certainty in degradation rates is expected to be the greatest source of LCOE reduction resulting from this project. Reducing the spread in the degradation rate probability distribution lowers project risk, which translates to lower project financing costs.

14 SOLAR ENERGY↗