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DOE OSTI2021

Revisiting the Effects of Photovoltaic Module Efficiency on Installed System Cost and Market Adoption

We conduct bottom-up analysis of how PV module efficiency could influence residential rooftop installed system costs, using models with improved representation of how soft costs and power electronics are affected by efficiency. We show that the amount of system installed cost savings resulting from high efficiency modules depends on whether or not the system is area-constrained, with much larger savings for the area-constrained case. We then estimate the fraction of physically area-constrained rooftops in the United States to be 61%, with variation between 20% to over 80% of rooftops depending on the state. We find that fraction of area-constrained systems could grow to over 88% by 2050 if building and transportation loads are electrified.

efficiency↗

DOE OSTI2020

The Effect of Photovoltaic Module Efficiency on Installed System Costs and Markets in Residential Rooftop Installations in the United States

In this report, we analyze how efficiencies influence residential PV system installed system costs and break-even module prices using a bottom-up cost model. We show that the cost savings associated with efficiency are much higher for area-constrained rooftop than those which are usage-constrained. We also show that simplified models of how efficiency impacts costs overestimate the value of efficiency compared to bottom-up models, particularly for usage-constrained scenarios. We also estimate the fraction of area-constrained residential rooftops in the United States today and explore how that fraction could change in future scenarios with high levels of electrification.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2018

A New Model to Determine Installed System Cost and LCOE for ARPA-E's MOSAIC Micro-Concentrator PV Program: Preprint

The US Department of Energy's Advanced Research Projects Agency-Energy (ARPA-E) started a three-year program in December 2015 called Microscale Optimized Solar-cell Arrays with Integrated Concentration (MOSAIC). It consists of 11 teams from across the United States. Its goal is to have project teams leverage expertise from conventional flat-plate photovoltaic (PV) system configuration and concentrated photovoltaic (CPV) module technology to produce a new class of modules for residential, commercial, and utility-scale markets. The intent is to increase performance and facilitate cost-effective deployment of solar power systems across a wide range of geographical locations in part by concentrating both direct and diffuse components of the sun's irradiance. This paper describes a collaboration of ARPA-E and the National Renewable Energy Laboratory (NREL) to develop a bottom-up system cost model for MOSAIC research teams. The model includes an estimate of regional, all-in, CPV installed cost, and levelized cost of energy (LCOE) by using customized inputs parameters, such as module efficiency, cost, and physical dimensions. This techno-economic cost model can help researchers analyze tradeoffs among different design parameters and then prioritize their distinct research opportunities. Moreover, it establishes a standardized cost benchmarking for MOSAIC micro-CPV systems and a normalized comparison against traditional CPV and today's highly competitive flat-plate PV systems. The model is a valuable design tool within the program, helping validate the various technical approaches and compare future deployed system competitiveness versus incumbent technologies in the PV industry.

14 SOLAR ENERGY↗

DOE OSTI2021

Floating Photovoltaic System Cost Benchmark: Q1 2021 Installations on Artificial Water Bodies

In this report, we conduct a bottom-up analysis of the installed costs for FPV systems deployed on artificial water bodies under average site conditions (wind load of about 40 m/s, snow load of 20 psf, water depth of 50 m, water level variation of 10 m, and swell height of 1 m). We estimate an installed system cost premium of $\$0.26$/WDC (25%) for 10-MWDC fixed-tilt FPV systems, compared with ground-mounted, fixed-tilt PV installed over bare ground. Higher structural costs related to the floats and anchoring system are the largest contributors to this premium. Currently, site investigation costs are also higher for FPV because of the additional effort needed to plan and design these more complex installations. Our preliminary sensitivity analysis shows that the installed cost of FPV systems is most sensitive to float costs, wind and snow loading, and module efficiency. FPV deployment is in an early stage, and additional experience, best practice development, and new configurations and technologies could help reduce the costs of FPV systems over time.

14 SOLAR ENERGY↗

DOE OSTI2025

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗

DOE OSTI2022

Evaluating the Impact of Residential Solar Contract Cancellations in the United States

The residential solar photovoltaic (PV) market in the United States is growing, despite frequent customer cancellations. Contract cancellations result in lost time and costs that must be borne by installers, often in the form of higher "soft costs" (i.e., non-equipment costs). These costs are often passed on to customers who successfully install PV systems. To date, few studies have attempted to estimate national cancellation rates or model the impacts on installed system costs. In this report, we utilize an installer-provided dataset of 199,665 residential PV-only projects representing about 10% of U.S. installs each year from 2017-2019. With this data, we evaluate cancellation rates and trends from contract signing to install. Next, by leveraging NREL's soft cost model for residential solar, we estimate installer spending through each phase of the pre-install process. Applying our findings on cancellation timelines and rates, we then estimate the potential cost impacts to successful installs from contract cancellations. Our work suggests that the rates and impacts of contract cancellations have been previously underestimated. Namely, we find that cancellations/unsuccessful project are; more common than previous estimates suggest; occur earlier in project timelines, though a significant number happen even after permit/ATB approvals; and contribute significantly to customer acquisition and other soft costs. We also find that cancellation do not appear to be driven by review delays in permitting and interconnection applications.

14 SOLAR ENERGY↗

DOE OSTI2017

U.S. Solar Photovoltaic System Cost Benchmark: Q1 2017

This report benchmarks U.S. solar photovoltaic (PV) system installed costs as of the first quarter of 2017 (Q1 2017). We use a bottom-up methodology, accounting for all system and projectdevelopment costs incurred during the installation to model the costs for residential, commercial, and utility-scale systems. In general, we attempt to model the typical installation techniques and business operations from an installed-cost perspective. Costs are represented from the perspective of the developer/installer; thus, all hardware costs represent the price at which components are purchased by the developer/installer, not accounting for preexisting supply agreements or other contracts. Importantly, the benchmark also represents the sales price paid to the installer; therefore, it includes profit in the cost of the hardware, 1 along with the profit the installer/developer receives, as a separate cost category. However, it does not include any additional net profit, such as a developer fee or price gross-up, which is common in the marketplace. We adopt this approach owing to the wide variation in developer profits in all three sectors, where project pricing is highly dependent on region and project specifics such as local retail electricity rate structures, local rebate and incentive structures, competitive environment, and overall project or deal structures. Finally, our benchmarks are national averages weighted by state installed capacities.

14 SOLAR ENERGY↗

DOE OSTI2020

Capital Costs for Dual-Use Photovoltaic Installations: 2020 Benchmark for Ground-Mounted PV Systems with Pollinator-Friendly Vegetation, Grazing, and Crops

This report analyzes the installed system cost of various multi-land use PV system configurations. We used PV system bottom-up cost model accounting for all system and project-development costs incurred during the installation to model the costs for conventional PV systems, PV systems co-located with sheep grazing, PV systems co-located with pollinator friendly fields and PV systems co-located with crops. We also conducted extensive sensitivity analysis around different PV system design parameters given the nascent stage of this industry.

14 SOLAR ENERGY↗

DOE OSTI2013

3-Port Single-Stage PV & Battery Converter Improves Efficiency and Cost in Combined PV/Battery Systems

Due to impressive cost reductions in recent years, photovoltaic (PV) generation is now able to produce electricity at highly competitive prices, but PV’s inherent intermittency reduces the potential value of this energy. The integration of battery storage with PV will be transformational by increasing the value of solar. Utility scale systems will benefit by firming intermittency including PV ramp smoothing, grid support and load shifting, allowing PV to compete directly with conventional generation. For distributed grid-tied PV adding storage will reduce peak demand utility charges, as well as providing backup power during power grid failures. The largest long term impact of combined PV and battery systems may be for delivering reliable off-grid power to the billions of individuals globally without access to conventional power grids, or for billions more that suffer from daily power outages. PV module costs no longer dominate installed PV system costs. Balance-of-System (BOS) costs including the PV inverter and installation now contribute the majority of installed system costs. Battery costs are also dropping faster than installation and battery power converter systems. In each of these separate systems power converters have become a bottleneck for efficiency, cost and reliability. These bottlenecks are compounded in hybrid power conversion systems that combine separate PV and battery converters. Hybrid power conversion systems have required multiple power converters hardware units and multiple power conversion steps adding to efficiency losses, product and installation costs, and reliability issues. Ideal Power Converters has developed and patented a completely new theory of operation for electronic power converters using its indirect EnergyPacket Switching™ topology. It has established successful power converter products for both PV and battery systems, and its 3-Port Hybrid Converter is the first product to exploit the topology’s capability for the industry’s first single-stage multi-port hybrid power converter. This unique low cost approach eliminates the hybrid power conversion bottlenecks when integrating batteries into PV systems. As result this product will significantly accelerate market adoption of these systems.

14 SOLAR ENERGY↗

DOE OSTI2022

Application of Manufacturing Quality Management Principles to PV System Installations

To help SETO/DOE achieve its goals, the IBTS team proposed a project addressing system reliability by improving installation standards and quality management. The proposed approach was designed to help achieve measurable reductions in installation defect density and improvements in the performance of PV systems by optimizing design and installation of residential and commercial PV systems. This approach addressed the soft costs associated with installations and quality management. The project demonstrated improved system reliability and reduced PV system installation costs. The software developed improved operations, decreased risk, and increased the overall value of PV systems across their lifecycle. The project used several data collection methods, including extensive industry surveys, face-to-face high-level interviews at industry conferences, stakeholder teleconferences, and in-depth interviews conducted by IBTS staff. Results from the research found the industry needs a uniform assessment method for national providers to be more efficient; the software should support both code officials and installers; most industry stakeholders would find value in a centralized software system that allows them to collect, report, and review information on in-process and completed solar installations; and mobile solutions that bridge existing knowledge gaps with inspectors and integrate with existing methodologies (such as permitting software) are of great value. The software solution developed is web-based, allowing for national access, and is built on a Google Firebase platform that can handle significant users and data. It can be used onsite or remotely, allowing for code compliance to continue despite ongoing pandemic related delays or shutdowns for local economies. The information provided by the software tool allows users to uniformly assess a system for compliance and use that aggregated data to identify training topics or create internal process designed to improving issues and reducing occurrence. This solution has multiple benefits in managing quality at time of use and promoting an increase in future safety and quality through education. Perhaps most importantly, this software increases public safety by ensuring compliance of installed systems and allows for local AHJs to remotely engage specialized and qualified solar specific expertise for oversite of the installation in their jurisdictions. Data analysis provides the quality feedback loop identifying the root cause of failure and drives installation practices to improve through training and education, resulting in systems with higher performance, greater reliability, and reduced operations and maintenance costs. With the successful completion of this project, the industry can expect reduced soft costs and increased performance and safety and will ultimately benefit from longer performing systems that cost less to operate.

14 SOLAR ENERGY↗

DOE OSTI2014

Building America Case Study: Evaluation of Residential Integrated Space/Water Heat Systems, Illinois and New York (Fact Sheet)

This multi-unit field demonstration of combined space and water heating (combi) systems was conducted to help document combi system installation and performance issues that needed to be addressed through research. The objective of the project was to put commercialized forced-air tankless combi units into the field through local contractors that were trained by manufacturers and GTI staff under the auspices of utility-implemented Emerging Technology Programs. With support from PARR, NYSERDA and other partners, the project documented system performance and installations in Chicago and New York. Combi systems were found to save nearly 200 therms in cold climates at efficiencies between about 80% and 94%. Combi systems using third-party air handler units specially designed for condensing combi system operation performed better than the packaged integrated combi systems available for the project. Moreover, combi systems tended to perform poorly when the tankless water heaters operating at high turn-down ratios. Field tests for this study exposed installation deficiencies due to contractor unfamiliarity with the products and the complexity of field engineering and system tweaking to achieve high efficiencies. Widespread contractor education must be a key component to market expansion of combi systems. Installed costs for combi systems need to come down about 5% to 10% to satisfy total resource calculations for utility-administered energy efficiency programs. Greater sales volumes and contractor familiarity can drive costs down. More research is needed to determine how well heating systems such as traditional furnace/water heater, combis, and heat pumps compare in similar as-installed scenarios, but under controlled conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Performance and Techno-Economic Evaluation of a Three-Phase, 50-kW SiC-Based PV Inverter

The technical capabilities and benefits of silicon carbide (SiC) compared to silicon (Si) based power electronics converters as well as the premium associated with using SiC instead of Si are well understood. This work proves that the benefits provided by SiC, such as increased efficiency, would result in a lower levelized cost of energy (LCOE) compared to both commercially available, state-of-the-art inverters and the benchmark commercial system cost calculated for the U.S. Department of Energy Solar Energy Technologies Office's SunShot program. The LCOE is calculated to be same as the commercial benchmark despite the installed system cost being 8% more than the benchmark. The LCOE calculation is based on both experiential values obtained from testing the SiC photovoltaic (PV) inverter and on the bottoms-up modeled volume cost for the same 50-kW SiC-based inverter. The PV system used for the LCOE model is also explained, and the system cost breakout is presented in this paper. Furthermore, multiple scenarios with variations in the PV system are presented to show their effect on the system LCOE.

14 SOLAR ENERGY↗

DOE OSTI2020

Analysis of the Value Proposition of High-Efficiency, Multijunction Solar Modules for Residential Rooftop Installations

Utilizing detailed bottom-up models, we analyze the potential markets for high-efficiency photovoltaic modules in the United States. We first estimate the fraction of area-constrained residential rooftops that could benefit from increasing the availability of high-efficiency systems. We then model the impact of efficiency on installed system costs in these area-constrained scenarios. Finally, we explore the value proposition of high-efficiency, fixed-tilt micro-concentrator photovoltaic modules in a series of case studies of residential customers, modeling the levelized cost of energy, payback period, and annual bill savings. We find that efficiency can provide significant savings in installed system cost and improve value to the solar system owner. The improvement in value depends on location and the size of the rooftop, as well as the ability of a given technology to collect diffuse light and achieve low module costs.

14 SOLAR ENERGY↗

DOE OSTI2021

U.S. Solar Photovoltaic System and Energy Storage Cost Benchmark (Q1 2020)

This report benchmarks U.S. solar photovoltaic (PV) system installed costs as of the first quarter of 2020 (Q1 2020). We use a bottom-up method, accounting for all system and project-development costs incurred during the installation to model the costs for residential (with and without storage), commercial (with and without storage), and utility-scale systems (with and without storage). We also incorporate other system characteristics and performance factors, as well as ongoing costs, to benchmark LCOE for PV-standalone systems, and LCOSS for solar+storage.

14 SOLAR ENERGY↗

DOE OSTI2021

Photovoltaic (PV) Module Technologies: 2020 Benchmark Costs and Technology Evolution Framework Results

This report benchmarks 2020 PV module minimum sustainable price (MSP) via bottom-up manufacturing cost analysis, for established PV technologies in mass production, including crystalline silicon, cadmium telluride (CdTe), and copper indium gallium (di)selenide. We provide technology roadmaps to additional MSP reductions for these PV technologies. Separately, we consider III-V and perovskite PV technologies which are currently in small-scale or pilot production. Finally, this report uses a technology evolution framework (TEF) to analyze drivers of levelized cost of energy reductions, including installed system cost - which is heavily influenced by module price - as well as service life and annual energy yield.

14 SOLAR ENERGY↗

DOE OSTI2018

2018 U.S. Utility-Scale Photovoltaics-Plus-Energy Storage System Costs Benchmark

Market growth for utility-scale photovoltaic (PV) systems has been rapid for several years. Today, with the cost reductions of energy storage technologies, the combining PV and energy storage has become feasible and beneficial, especially for the areas that have only PV standalone systems and need to shift the peak load to meet electricity demand in the evening. Overall, utility-scale PV plus energy storage systems can provide dispatchable energy and reliable capacity. This study details cost factors, including labor costs, material costs, overhead, and permitting costs using a system-level bottom-up cost modeling approach. We use this model to benchmark PV-plus-storage installation system cost and identify the cost difference for AC- and DC-coupled systems and duration variation. Finally, we assess the cost reduction opportunities of colocating PV systems with energy storage systems in order to indicate the possible economic impacts of the PV-plus-storage configuration and help future research and development (R&D) effects in the context of U.S. energy storage policymaking.

14 SOLAR ENERGY↗

DOE OSTI2018

2018 U.S. Utility-Scale Photovoltaics-Plus-Energy Storage System Costs Benchmark

14 SOLAR ENERGY↗

DOE OSTI2018

Evaluating the Cost Benefits of U.S. Utility-Scale Photovoltaics Plus Energy Storage Systems

Utility-scale photovoltaics (PV) system market growth has been rapid for several years. Today, with the cost reductions of energy storage technologies, the application of combing PV and energy storage has become feasible and beneficial, especially for the areas that only have PV standalone systems and need to shift the peak load to meet the evening electricity demand. Overall, the utility-scale PV plus energy storage systems can provide dispatchable energy and reliable capacity. This study details cost factors, including labor costs, material costs, overhead, and permitting costs using a systemlevel bottom-up cost modeling approach. We use this model to benchmark PV plus storage installation system cost and identify cost difference for AC and DC coupled systems and duration variation. Finally, we assess the cost reduction opportunities of co-locating PV system with energy storage system in order to indicate the possible economic impacts of PV plus storage configuration and help future research and development (R&D) effects in the context of U.S. energy storage policymaking.

14 SOLAR ENERGY↗