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DOE OSTI2020

Light and Elevated Temperature Induced Degradation (LeTID) in a Utility-Scale Photovoltaic System

Here, we present a detailed case study of degradation in monocrystalline silicon photovoltaic modules operating in a utility-scale power plant over the course of approximately three years. We present the results of degradation analysis on arrays within the site, and find that five of the six arrays degraded faster than the best performing array, even though the arrays consist of modules of the same manufacturer and model. We also describe the results of extensive laboratory characterization of modules returned from the field, including module- and cell-level current–voltage characterization, luminescence imaging, and accelerated testing. The laboratory test results and the field performance are consistent with light and elevated temperature induced degradation (LeTID). Notably, we observe differences in back contact technology between affected and unaffected modules. This article also demonstrates a method to identify possible LeTID degradation in the field and confirm the result with laboratory testing of a small number of modules.

14 SOLAR ENERGY↗

DOE OSTI2025

Uniform Mechanical Loading Can Test for Nonuniform Loading Durability

In this work, we present a method to evaluate the equivalency between any module mechanical loading conditions. The method is developed to address the specific failure mode of glass fracture and is based on Weibull analysis and weakest link theory. It considers the varying stress profile across the module to calculate the probability of glass fracture, which is used as the metric of equivalency. An idealized nonuniform loading scheme is employed to demonstrate the method and introduce the concept of the equivalent uniform load factor: a factor applied to the maximum pressure of the nonuniform load to obtain the equivalent uniform load value. It is demonstrated that this factor is less than unity for all nonuniform load cases considered, including snow and various characters of wind loading. These significant results suggest that uniform loading may be reliably, and practically, employed to evaluate photovoltaic module glass for nonuniform loading durability.

14 SOLAR ENERGY↗

DOE OSTI2018

Real‐time monitoring and diagnosis of photovoltaic system degradation only using maximum power point—the Suns‐Vmp method

Abstract The uncertainties associated with technology‐specific and geography‐specific degradation rates make it difficult to calculate the levelized cost of energy, and thus the economic viability of solar energy. In this regard, millions of fielded photovoltaic modules may serve as a global testbed, where we can interpret the routinely collected time series maximum power point (MPP) data to assess the time‐dependent “health” of solar modules. The existing characterization methods, however, cannot effectively mine/decode these datasets to identify various degradation pathways. In this paper, we propose a new methodology called the Suns‐Vmp method , which offers a simple yet powerful approach to monitoring and diagnosing time‐dependent degradation of solar modules by using the MPP data. The algorithm reconstructs “IV” curves by using the natural illumination‐dependent and temperature‐dependent daily MPP characteristics as constraints to fit physics‐based circuit models. These synthetic IV characteristics are then used to determine the time‐dependent evolution of circuit parameters (eg, series resistance), which in turn allows one to deduce the dominant degradation modes (eg, solder bond failure) of solar modules. The proposed method has been applied to a test facility at the National Renewable Energy Laboratory. Our analysis indicates that the solar modules degraded at a rate of ~0.7%/year because of discoloration and weakened solder bonds. These conclusions are validated by independent outdoor IV measurements and on‐site imaging characterization. Integrated with physics‐based degradation models or machine learning algorithms, the method can also serve to predict the lifetime of photovoltaic systems.

Sun, Xingshu↗

NASA NTRS1978

Impact of Balance Of System (BOS) costs on photovoltaic power systems

The Department of Energy has developed a program to effect a large reduction in the price of photovoltaic modules, with significant progress already achieved toward the 1986 goal of 50 cents/watt (1975 dollars). Remaining elements of a P/V power system (structure, battery storage, regulation, control, and wiring) are also significant cost items. The costs of these remaining elements are commonly referred to as Balance-of-System (BOS) costs. The BOS costs are less well defined and documented than module costs. The Lewis Research Center (LeRC) in 1976/77 and with two village power experiments that will be installed in 1978. The costs were divided into five categories and analyzed. A regression analysis was performed to determine correlations of BOS Costs per peak watt, with power size for these photovoltaic systems. The statistical relationship may be used for flat-plate, DC systems ranging from 100 to 4,000 peak watts. A survey of suppliers was conducted for comparison with the predicted BOS cost relationship.

Hein, G. F.↗

DOE OSTI2020

Improved Performance of Cu(InGa)(SeS) 2 PV Modules Using the Reaction of Metal Precursors. Final Report

This project “Improved Performance of Cu(InGa)(SeS) 2 PV Modules using the Reaction of Metal Precursors” was a partnership led by the Institute of Energy Conversion (IEC) at the University of Delaware with Columbia University and the Molecular Foundry at the Lawrence Berkeley National Laboratory. The aim was to develop pathways to improve Cu(InGa)(SeS) 2 (CIGSS) thin film photovoltaic modules using processes compatible with low manufacturing cost. The CIGSS approach investigated was a two-step process including deposition of metal precursor films following by reaction in hydride gases utilizing IEC’s novel reactor. The process was similar to that under commercial development by the project’s industry partner Stion. When Stion went out of business mid-project the focus changed to a rapid thermal process considered more commercially viable. Approaches to improve the performance of solar cells using the reacted films focused on two material innovations. First, the overall Ga content was increased to increase the operating voltage, which is desirable for scale-up to commercial modules. Second, the processing and performance advantages arising from Ag alloying were investigated. Advanced characterization guided process and material development including control of relative composition gradients. Research on the formation of Cu-Ga-In metal precursors utilized sputtering deposition which is normally used in commercial applications. The work resulted in processes for deposition of precursor stacks with increased relative Ga content and effects of deposition parameters on morphology and phase composition were established. It was shown that the metal precursor films have comparable phase composition and morphology so subsequent reaction follows from the same starting point. The addition of Ag to the metal precursors gave more uniform morphology and improved adhesion of reacted films which enable higher reaction temperature for faster processing. A novel outcome was the discovery of a previously undocumented material phase in sputter-deposited and evaporated Ag-Cu-In-Ga thin films. Hydride gas reaction processes including time-temperature-concentration profiles were developed for different precursor compositions. This enables control of composition profiles to engineer through-film gradients for solar cell optimization with characterization and simulations used to correlate measured film composition profiles to measurements of devices. In particular, the gradient of sulfur at the front of the CIGSS film was found to be critical. The simulations guided process development leading to improved reproducibility of devices improved performance with higher Ga content and higher voltage. With Ag-alloyed precursors, the reaction pathways leading were determined. A significant finding was that Ag-alloying increases the reaction rate to completely convert precursor films to the final chalcopyrite which could enable reduced reaction time to benefit manufacturability. To maintain potential commercial viability, the process under investigation was refocused to a rapid thermal process that could potentially be incorporated into an in-line process for manufacturing. Precursors with different composition were capped with an extra selenium layer and reacted in hydrogen sulfide 5-15 minutes, compared to typically 2 hours in the previous multi-step batch process. Critical RTP parameters were identified to control the reaction. Further optimization would be needed for high efficiency solar cells but pathways to high quality devices with further optimization and improved heating uniformity were developed. The project also developed new optoelectronic characterization approaches with a focus on development and application of spatial- and time-resolved photoluminescence and a custom mapping photoluminescence microscope built. It was shown how critical electronic transport properties strongly depend on the chemical composition of the material and that a wide range of samples show inhomogeneity on a length scale larger than the grains in the films. Additionally, two-photon excitation capability was developed to distinguish bulk vs surface losses. The project advances the state-of-the -art for precursor reaction processes in several ways that could impact manufacturing. This includes validation of approaches to increase voltage and establishment of model-guided control to form optimal composition profiles. The application of process control approaches with knowledge of phase formation and reaction pathways can be critically valuable in designing a large-scale process.

14 SOLAR ENERGY↗

DOE OSTI2020

Suggested Modifications for Bifacial Capacity Testing

Capacity tests such as those described in ASTM 2848 and IEC 61724-2 are widely used during the contracting and acceptance testing of photovoltaic systems. With the increasing deployment of bifacial photovoltaic modules, there is a need to develop a standardized approach to capacity test these systems. Although variability and bias error were inherently higher for the measured capacity of bifacial systems, they could be reduced to a level consistent with the monofacial reference system by appropriate incorporation of rear irradiance—either measured or modeled. Three field installations provided bifacial system capacity that was measured with a mean bias error and standard deviation within 1% over the 2–10-month observation period. Capacity test accuracy could be improved further by using the measured back-of-module temperature and the IEC 61724-2 test method for well curated systems.

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

DOE OSTI2017

Moisture ingress prediction in polyisobutylene-based edge seal with molecular sieve desiccant

Often photovoltaic modules are constructed with materials that are sensitive to water. This is most often the case with thin film technologies, including perovskite cells, where the active layers are a few microns thick and can be sensitive to moisture, liquid water or both. When moisture or liquid water can ingress, a small amount of water can lead to corrosion and depending on the resulting reactions, a larger local detrimental effect is possible. To prevent moisture from contacting photovoltaic components, impermeable frontsheets and backsheets are used with a polyisobutylene (PIB)-based edge seal material around the perimeter. Here, we evaluate the ability of a PIB-based edge seal using a molecular sieve desiccant to keep moisture out for the expected module lifetime. Moisture ingress is evaluated using test coupons where the edge seal is placed between 2 pieces of glass, one of which has a metallic calcium film on it, and monitoring the moisture ingress distance as a function of time. We expose samples to different temperature and humidity conditions to create permeation models useful for extrapolation to field use. This extrapolation indicates that this PIB material is capable of keeping moisture out of a module for the desired lifetime.

14 SOLAR ENERGY↗

NASA NTRS1981

Comparison of photovoltaic cell temperatures in modules operating with exposed and enclosed back surfaces

Four different photovoltaic module designs were tested to determine the cell temperature of each design. The cell temperatures were compared to those obtained on identical design, using the same nominal operating cell temperature (NOCT) concept. The results showed that the NOCT procedure does not apply to the enclosed configurations due to continuous transient conditions. The enclosed modules had higher cell temperatures than the open modules, and insulated modules higher than the uninsulated. The severest performance loss - when translated from cell temperatures - 17.5 % for one enclosed, insulated module as a compared to that module mounted openly.

Namkoong, D.↗

NASA NTRS1984

Module utilization committee

Photovoltaic collector modules were declared surplus to the needs of the U.S. Dept. of Energy. The Module Utilization Committee was formed to make appropriate disposition of the surplus modules on a national basis and to act as a broker for requests for these modules originating outside of the National Photovoltaics Program.

Volkmer, K.↗

DOE OSTI2018

System Dynamics of Polysilicon for Solar Photovoltaics: A Framework for Investigating the Energy Security of Renewable Energy Supply Chains

Renewable energy, produced with widely available low-cost energy resources, is often included as a component of national strategies to address energy security and sustainability. Market and political forces cannot disrupt the sun or wind, unlike oil and gas supplies. However, the cost of renewable energy is highly dependent on technologies manufactured through global supply chains in leading manufacturing countries. The countries that contribute to the global supply chains may take actions that, directly or indirectly, influence global access to materials and components. For example, high-purity polysilicon, a key material in solar photovoltaics, has experienced significant price fluctuations, affecting the manufacturing capacity and cost of both polysilicon and solar panels. This study has developed and validated an initial system dynamics framework to gain insights into global trade in polysilicon. The model represents an initial framework for exploration. Three regions were modeled-China, the United States, and the rest of the world - for a range of trade scenarios to understand the impacts of import duties and non-price drivers on the relative volumes of imports and domestic supply. The model was validated with the historical case of China imposing an import duty on polysilicon from the United States, the European Union, and South Korea, which altered the regional flows of polysilicon - in terms of imports, exports, and domestic production-to varying degrees. As expected, the model tracked how regional demand shares and influx volumes decrease as a duty on a region increases. Using 2016 as a reference point, in the scenarios examined for U.S. exports to China, each 10% increase in the import duty results in a 40% decrease in import volume. The model also indicates that, under the scenarios investigated, once a duty has been imposed on a region, the demand share from that region declines and does not achieve pre-duty levels, even as global demand increases. Adding additional countries and other components in the photovoltaic supply chain (panels, cells, wafers) to this model could enable policymakers to better understand the relative impact of trade measures across the entire photovoltaic module manufacturing supply chain and the conditions that encourage industry evolution and competitiveness.

14 SOLAR ENERGY↗

DOE OSTI2020

Potential of module arrangements to enhance convective cooling in solar photovoltaic arrays

Not provided.

Energy & Fuels↗

NASA NTRS1980

Design, fabrication, test, qualification and price analysis for third generation design solar cell modules

An updated program plan is presented showing the task descriptions depicting the work, progress, achievements, and the cause of any deviations from the original plan (SC-1), and how this impacted on the original schedule of the program. In addition there is an update documenting all design alterations made during the pre-production phase and a complete up to date set of engineering and manufacturing documentation (CM-1). The purpose of the work in the original plan was to explore, design, develop, test, and deliver 1000 watts of prototype flat plate, photovoltaic modules appropriate for use in applications in the 20 to 500 kilowatt range and which show potential for meeting the 1986 cost goals.

Source record↗

DOE OSTI2023

On the uncertainty of estimating photovoltaic soiling using nearby soiling data

The accumulation of dust on the surface of photovoltaic modules can reduce their performance and affect the cost competitiveness of this technology. This phenomenon is known as soiling and can be mitigated through appropriate corrective and/or preventive actions. In order to maximize its effectiveness, it is important to plan the soiling mitigation strategy even before the PV system is operational. This is typically done through a nearest neighbor approach, by estimating soiling using data from the nearest operational photovoltaic system. This work focuses on understanding the uncertainty related to this practice. For this purpose, the semi-variance function is used to study the dissimilarity between the soiling losses of two locations in California depending on their distance. The results show that, when the soiling loss at a nearby system is used to estimate soiling of a site, the uncertainty can be approximated to increase linearly at a rate of 0.08-0.10%/km up to 60 or 80 km. After this distance, the use of a nearest neighbor approach is no longer justified, as it produces an uncertainty as big as the average soiling loss of the sites in the dataset used in this study. In some conditions, uncertainties > 0% are found also for sites located within 25 km, meaning that even close-by systems might soil differently.

14 SOLAR ENERGY↗

DOE OSTI2021

Outdoor performance of a tandem InGaP/Si photovoltaic luminescent solar concentrator

Here, we report the design, fabrication and outdoor characterization of a tandem luminescent solar concentrator/Si multi-junction photovoltaic module. Our tandem LSC/Si device consists of an InGaP LSC functioning as a top cell and a passivated contact Si bottom cell. The LSC comprises of an InGaP microcell array coupled to a polymer waveguide, loaded with CdSe/CdS core-shell quantum dot luminophores. The light trapping efficiency of the LSC waveguide is enhanced by encapsulation with photoluminescence trapping mirrors consisting of dielectric multilayer thin films. We demonstrate the performance of the LSC/Si device through a series of outdoor tests under various irradiance conditions conducted at the National Renewable Energy Laboratory. We report the first outdoor testing data of an LSC/Si tandem module, displaying maintained performance across varied diffusivity conditions for the LSC component. Finally, we model the tandem module performance using a ray optic simulation-based multiphysics model and forecast a pathway for high efficiency tandem LSC/Si module performance.

14 SOLAR ENERGY↗

DOE OSTI2021

Corrosion of novel reactive silver ink and commercial silver-based metallizations in diluted acetic acid

Silver-based metallizations in photovoltaic modules are susceptible to corrosion by acetic acid generated in ethylene vinyl acetate encapsulated modules, resulting in power losses over time. Here, three silver-based metallizations are exposed to diluted acetic acid, in concentrations representative of that found in field-exposed modules. Compositional, morphological, and structural changes of the metallizations are studied over 3000 h of exposure to diluted acetic acid using Raman spectroscopy mapping, X-ray diffraction, and scanning electron microscopy. The three metallizations studied are: 1) a commercial high-temperature fire-through Ag paste, commonly used for Si diffused junction solar cells; 2) a commercial low-temperature paste normally used for silicon heterojunction cells; and 3) a novel low-temperature reactive silver ink shown to be suitable for photovoltaic applications. We find distinct corrosion rates for the high-temperature silver paste and reactive silver ink in the presence of diluted acetic acid. However, the low-temperature silver paste appears to be more corrosion resistant, likely due to a polymer layer that protects the silver particles.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Innovative Ballasted Flat Roof Solar PV Racking System

The objective of this project was to reduce the cost of racking for PV solar on flat commercial rooftops. Cost reductions would come from both labor savings and material savings related to the installation process. The rack would need to accommodate the majority of modules available on the market. Cascade Engineering has a long history of converting traditional metal type applications over to plastic. Injection molding of plastics have numerous advantages including selection of resin for the application, placing the material exactly where it is needed, designing in features that will speed up the installation process, and weight reduction of the array. A plastic rack would need to meet the requirements of UL2703, Mounting systems, mounting devices, clamping/retention devices, and ground lugs for use with flat-plate photovoltaic modules and panels. Comparing original data to the end of project racking design, racking material costs were reduced 50% and labor costs reduced 64%. The racking product accommodates all 60 and 72 cell panels on the market, meets UL2703 requirements, contributes only 1.3 pounds per square foot of weight to the array, requires little ballast to secure the array, automatically grounds the module when the module is secured, stacks/nests well for shipping/fewer lifts to the roof, provides integrated wire routing, allows water to drain on the roof, and accommodates various seismic roof connections. Project goals were achieved as noted in the original funding application.

14 SOLAR ENERGY↗

DOE OSTI2019

Vertically stacked photovoltaic and thermal solar cell

According to some embodiments, the present invention provides a novel photovoltaic solar cell system from photovoltaic modules that are vertically arrayed in a stack format using thin film semiconductors selected from among organic and inorganic thin film semiconductors. The stack cells may be cells that are produced in a planar manner, then vertically oriented in an angular form, also termed herein tilted, to maximize the light capturing aspects. The use of a stack configuration system as described herein allows for the use of a variety of electrode materials, such as transparent materials or semitransparent metals. Light concentration can be achieved by using fresnel lens, parabolic mirrors or derivatives of such structures. The light capturing can be controlled by being reflected back and forth in the photovoltaic system until significant quantities of the resonant light is absorbed. Light that passes to the very end and can be reflected back through the device by beveling or capping the end of the device with a different refractive index material, or alternatively using a reflective surface. The contacting between stacked cells can be done in series or parallel. According to some embodiments, the present invention uses a concentrator architecture where the light is channeled into the cells that contain thermal fluid channels (using a transparent fluid such as water) to absorb and hence reduce the thermal energy generation.

14 SOLAR ENERGY↗

DOE OSTI2020

Vertically stacked photovoltaic and thermal solar cell

14 SOLAR ENERGY↗