Embracing Cost-effective Solar Production: Leveraging Automation and Technological Advancements

An essential factor contributing to the growth of crystalline silicon photovoltaics is the adoption of cheaper production tools with higher productivity. This has led to significant improvements in various aspects of solar cell production, making it more cost-effective and efficient. In this section, we will discuss some of these advancements in detail.

1. Enhanced Automation: The increased use of automation in production processes has improved labor productivity significantly. From 2010 to 2020, the number of direct labor (DL) required per 1 MW of annual production reduced from 10 DL to less than 1 DL MW-1. This reduction in labor costs has positively impacted the overall manufacturing expenses.
2. Larger Cells: The size of solar cells has also increased over the years, contributing to enhanced efficiency. In 2010, the standard wafer size was 125 mm square, which increased to 166 mm in 2020, and even up to 210 mm. The larger cell sizes enable the production of more powerful solar modules.
3. Thinner Wafers and Reduced Kerf-loss: Another advancement is the reduction in wafer thickness and kerf-loss during the slicing process. The diameter of wires for slicing silicon wafers has decreased from approximately 150 µm to less than 50 µm over the last decade. This results in less material wastage and cost savings during production.
4. Increased Wafer Capacity in Diffusion Furnaces: The wafer capacity per batch in diffusion furnaces has also grown significantly. From handling around 500 wafers per batch in 2010, the capacity increased to 1600 wafers per batch in 2020. This higher throughput enables manufacturers to produce more solar cells at a faster pace, further reducing production costs.

These advancements in solar cell production have contributed to the rapid decrease in manufacturing costs and the continued increase in efficiency and module power. As the solar industry continues to innovate and optimize production processes, we can expect further enhancements in the affordability and effectiveness of crystalline silicon photovoltaics, paving the way for a more sustainable future.