Detailed Project Report on solar cell & module manufacturing unit

SOLAR CELL & MODULE MANUFACTURING UNIT

[CODE NO.4141] 

A solar cell (also known as a photovoltaic cell or PV cell) is defined as an electrical device that converts light energy into electrical energy through the photovoltaic effect. A solar cell is basically a p-n junction diode. Solar cells are a form of photoelectric cell, defined as a device whose electrical characteristics – such as current, voltage, or resistance – vary when exposed to light.

Individual solar cells can be combined to form modules commonly known as solar panels. The common single junction silicon solar cell can produce a maximum open-circuit voltage of approximately 0.5 to 0.6 volts. By itself this isn’t much – but remember these solar cells are tiny. When combined into a large solar panel, considerable amounts of renewable energy can be generated.

PV Module or Solar PV Module is an assembly of photovoltaic (PV) cells, also known as solar cells. To achieve a required voltage and current, a group of PV modules (also called PV panels) are wired into large array that called PV array. A PV module is the essential component of any PV system that converts sunlight directly into direct current (DC) electricity. PV modules can be wired together in series and/or parallel to deliver voltage and current in a particular system requires.

PV is emerging as a major power resource, steadily becoming more affordable and proving to be more reliable than utilities. Photovoltaic power promises a brighter, cleaner future for our children.

Using the technology we have today we could equal the entire electric production of the United States with photovoltaic power plants using only about 12,000 square miles. 

In 1839, Edmund Becquerel discovered the process of using sunlight to produce an electric current in a solid material, but it wasn't until a century later that scientists eventually learned that the photovoltaic effect caused certain materials to convert light energy into electrical energy. 

The photovoltaic effect is the basic principal process by which a PV cell converts sunlight into electricity. When light shines on a PV cell, it may be reflected, absorbed, or pass right through. The absorbed light generates electricity. 

In the early 1950s, photovoltaic (PV) cells were developed as a spin-off of transistor technology. Very thin layers of pure silicon are impregnated with tiny amounts of other elements. When exposed to sunlight, small amounts of electricity are produced. Originally this technology was a costly source of power for satellites but it has steadily come down in price making it affordable to power homes and businesses.

CELLS MODULES AND ARRAYS

Photovoltaic cells are connected electrically in series and/or parallel circuits to produce higher voltages, currents and power levels. Photovoltaic modules consist of PV cell circuits sealed in an environmentally protective laminate, and are the fundamental building blocks of PV systems. Photovoltaic panels include one or more PV modules assembled as a pre-wired, field-installable unit. A photovoltaic array is the complete power-generating unit, consisting of any number of PV modules and panels.

  Photovoltaic cells, modules, panels and arrays

The performance of PV modules and arrays are generally rated according to their maximum DC power output (watts) under Standard Test Conditions (STC). Standard Test Conditions are defined by a module (cell) operating temperature of 25o C (77o F), and incident solar irradiance level of 1000 W/m2 and under Air Mass 1.5 spectral distribution. Since these conditions are not always typical of how PV modules and arrays operate in the field, actual performance is usually 85 to 90 percent of the STC rating.

Today’s photovoltaic modules are extremely safe and reliable products, with minimal failure rates and projected service lifetimes of 20 to 30 years. Most major manufacturers offer warranties of 20 or more years for maintaining a high percentage of initial rated power output. When selecting PV modules, look for the product listing (UL), qualification testing and warranty information in the module manufacturer’s specifications.

COST ESTIMATION

Plant Capacity                                     0.375 MW/Day

Land & Building (6000 sq.mt.)           Rs. 5.01 Cr

Plant & Machinery                                Rs. 14 Lac

Working Capital for 1 Month             Rs. 19.08 Cr

Total Capital Investment                     Rs. 24.96 Cr

• INTRODUCTION
  
• CELLS MODULES AND ARRAYS
• PHOTOVOLTAIC CELL
• PHOTOVOLTAIC MODULES
• COMMERCIAL PRODUCTION TECHNOLOGIES FOR PV
• SINGLE CRYSTALLINE
• POLYCRYSTALLINE OR MULTICRYSTALLINE
• AMORPHOUS OR THIN FILM
• PHOTOVOLTAIC PANELS
• PHOTOVOLTAIC ARRAY
• PROJECT LOCATION- LUNAWADA CITY
• LUNAWADA
• MAP
• TRANSPORTATION
• NEAR BY MAJOR CITIES
• NEAR BY AIR PORTS
• NEAR BY TOURIST PLACES
• NEAR BY LOCAL CITIES
• NEAR BY DISTRICTS
• NEAR BY RAILWAY STATION
• HISTORY OF PHOTOVOLTIC CELLS
• TYPES OF PV MODULE
• CRYSTALLINE SILICON PV MODULE
• SINGLE CRYSTALINE (MONO-CRYSTALLINE)
• CONSTRUCTION
• TECHNICAL SPECIFICATION
• ADVANTAGES OF MONOCRYSTALLINE PV MODULE
• DISADVANTAGES
• APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
• POLY-CRYSTALLINE (MULTI CRYSTALLINE)
• CONSTRUCTION
• ADVANTAGES OF POLYCRYSTALLINE PV MODULE
• DISADVANTAGES OF POLYCRYSTALLINE SOLAR PANELS
• CONSTRUCTION OF PV MODULE
• THE 6 MAIN COMPONENTS OF A SOLAR PANEL
• PV CELLS
• A MONOCRYSTALLINE SOLAR CELL
• GLASS
• FRAME
• EVA FILM
• BACK SHEET
• JUNCTION BOX
• BYPASS DIODES
• NUMBER OF CELLS IN MODULE
• PROS & CONS OF PV
• COMPLETE PHOTOVOLTAIC-BASED ELECTRICAL SYSTEMS
• PHOTOVOLTAIC MODULE PERFORMANCE
• PHOTOVOLTAIC APPLICATIONS
• PHOTOVOLTAIC BENEFITS
• SOLAR CELL I-V CHARACTERISTIC
• SOLAR CELL I-V CHARACTERISTIC AND THE SOLAR CELL I-V CURVE
• SOLAR CELL I-V CHARACTERISTIC CURVE
• THE ELECTRICAL CHARACTERISTICS OF A PHOTOVOLTAIC ARRAY
• SOLAR ARRAY PARAMETERS
• EXAMPLE OF I-V CURVE AND RATINGS OF A 12 V SOLAR (PV) PANEL
• IV CURVE
• IDEAL SOLAR CELL
• IDEAL SOLAR CELL (SIMPLIFIED)
• EFFECT OF TEMPERATURE
• THE AFFECTS OF IRRADIANCE
• EFFECT OF LIGHT INTENSITY
• CONCENTRATORS
• LOW LIGHT INTENSITY
• LINE CAPACITY
• SOLAR PV MODULE SPECIFICATION
• (A) MECHANICAL SPECIFICATION
• 1. SOLAR CELL TYPE
• 2. CELL DIMENSION (IN INCHES/MM.)
• 3. MODULE DIMENSION (IN INCHES/MM.)
• 4. MODULE WEIGHT (IN KGS./LBS.)
• 5. GLAZING OR FRONT GLASS
• 6. FRAME
• 7. OUTPUT CABLES
• 8. JUNCTION BOX
• (B) ELECTRICAL SPECIFICATION
• 1. PEAK POWER (W)
• 2. OPTIMUM OPERATING VOLTAGE
• 3. OPTIMUM OPERATING CURRENT
• 4. OPEN CIRCUIT VOLTAGE
• 5. SHORT CIRCUIT CURRENT
• 7. MODULE EFFICIENCY
• 8. OPERATING TEMPERATURE
• 9. MAX. SERIES FUSE RATING
• 10. POWER TOLERANCE
• 11. PARAMETERS DEFINED UNDER NOCT
• 12. TEMPERATURE COEFFICIENTS
• APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
• ADVANTAGES OF PV PANNEL
• DISADVANTAGES OF PV PANNEL
• USES AND APPLICATION OF PV POWER PLANT
• APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
• APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
• AGRICULTURE
• INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES
• HEALTH
• RESIDENTIAL
• B.I.S. SPECIFICATION
• HEADQUARTERS
• SALES OUTLETS ADDRESS
• TELEPHONE NO/FAX/E-MAIL
• PROCESS FLOW CHART FOR SOLAR PANEL
• FABRICATION PROCESS OF MONOCRYSTALLINE SOLAR PV MODULE
• A. SOLAR CELL
• B. EVA (ETHYLENE VINYL ACETATE)
• ENCAPSULANT’S (EVA) REQUIREMENTS
• C. BACKSHEET
• REQUIREMENTS OF REAR SURFACE
• D. GLASS
• REQUIREMENTS
• E. JUNCTION BOX WITH BYPASS DIODES AND CONNECTING CABLES JUNCTION
• CABLES JUNCTION BOX CONSISTS OF THE FOLLOWING
• F. CONNECTING RIBBON TWO TYPES OF CONNECTING RIBBON ARE
• G. SILICONE SEALANT
• SEALANT
• H. SHORT AND LONG FRAMES (BACKBONE OF THE MODULE STRUCTURE)
• MODULE ASSEMBLY STEPS
• MARKET POSITION
• PV MODULES MARKET – INDIA
• RISING IMPORTS
• DOMESTIC INDUSTRY WOES
• WAY FORWARD
• RISEN ENERGY
• WAAREE
• ZNSHINE
• VIKRAM SOLAR
• ADANI
• TRINA SOLAR
• RENESOLA
• JINKOSOLAR
• LONGI SOLAR
• CANADIAN SOLAR
• GLOBAL MARKET
• TECHNOLOGY INSIGHTS
• APPLICATION INSIGHTS
• GRID TYPE INSIGHTS
• REGIONAL INSIGHTS
• KEY COMPANIES & MARKET SHARE INSIGHTS
• PV PRODUCTION LINE
• M-01 AUTOMATIC GLASS LOADING
• FUNCTION
• DESCRIPTION
• MAIN FEATURES
• FEATURES GLL0205-2
• M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
• FUNCTION
• DESCRIPTION
• FEATURES FCM0304-2
• M-03 AUTOMATIC TEMPLATE LOADING
• FUNCTION
• DESCRIPTION
• FEATURES FCM0305-1
• M-04 INSPECTION TABLE
• FUNCTION
• CHARACTERISTICS
• FEATURES ICB2205-1
• ADVANTAGES
• M-05 TABBER AND STRINGER MTS-3000
• FUNCTION
• DESCRIPTION
• HIGHLIGHTS
• MAIN FEATURES
• CELL PARAMETERS
• TABS
• STRINGS
• TABBING & STRINGING
• PERFORMANCE FEATURES
• SYSTEM DIMENSIONS
• SYSTEM CONTROL & SOFTWARE
• LIST OF EQUIPMENT INCLUDED:
• M-06 LAY-UP SYSTEM
• FUNCTION
• HIGHLIGHTS
• FEATURES LUS2200-1
• M-07 MIRROR INSPECTION TABLE
• FUNCTION
• CHARACTERISTICS
• FEATURES ICB2200-1
• ADVANTAGES
• M-08 AUTOMATIC BUSSING IC100 (3 HEADS
• FUNCTION
• DESCRIPTION
• ADVANTAGES
• FEATURES ICB2001-1
• M-9 INTERCONNECTION CHECKING + LABEL PLACING
• FUNCTION
• CHARACTERISTICS
• FEATURES ICB2207-1
• ADVANTAGES
• M-10 EL INSPECTION
• FUNCTION
• CHARACTERISTICS
• FEATURES EL MA
• M-11 AUTOMATIC FOIL CUTTING AND LOADING
• FUNCTION
• DESCRIPTION
• FEATURES FCM0307-2
• M-12 BUFFER
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES BUF3501-1
• M-13 LAMINATOR
• FUNCTION
• DESCRIPTION
• ADVANTAGES OF OUR LAMINATORS
• FEATURES LAM3024-1
• M-14 AUTOMATIC EDGE TRIMMING
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• PROCESS DESCRIPTION
• FEATURES ETM3604-2
• M15 AUTOMATIC OPTICAL INSPECTION
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES VT5007-1
• OPTICAL INSPECTION
• M-16 AUTOMATIC FRAMING UNIT
• FUNCTION
• CHARACTERISTICS
• FEATURES FR4200-2
• AUTO FRAME FEEDER (OPTIONAL)
• M-17 JBOX WORKING TABLES
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• M-18 AUTOMATIC JBOX POTTING MACHINE
• FUNCTION
• CHARACTERISTICS
• FEATURES JBX3709-1
• M-19 JBOX POTTING DISPENSING MACHINE
• FUNCTION
• CHARACTERISTICS
• FEATURES JBX3707-1
• M-20 JBOX SILICONE DISPENSING MACHINE
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES JBX3707-1
• M-21 CURING LINE
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES CUR 6001-2
• M-22 MODULE TESTING STATION
• FUNCTION
• MAIN CHARACTERISTICS
• FEATURES IVT5006-1 ENDEAS QUICKSUN 600
• M-23 AUTOMATIC MODULE SORTING
• FUNCTION
• ADVANTAGES
• FEATURES SOR6102-1
• M-24 AUTOMATIC GLASS LOADING
• FUNCTION
• DESCRIPTION
• MAIN FEATURES
• FEATURES GLL0205-1
• M-25 SECOND GLASS LOADING
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES SGL0206-1
• M-26 AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES SOR6102-1
• M-27 AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
• FUNCTION
• HIGHLIGHTS
• PRECIOUS SEPARATION
• LOW CONSUMPTION
• FEATURES: GDS 50
• OFFLINE EQUIPMENT QUANTITY
• ACCESSORIES
• A-01 CELL TESTER
• FUNCTION
• CHARACTERISTICS
• ADVANTAGES
• FEATURES CLT0102-1
• ASSEMBLY LAYOUT
• LINE LAYOUT (PROPOSED)
• PLANT LAYOUT
• MANUFACTURERS/SUPPLIERS OF SOLAR PV MODULE
• RAW MATERIAL SUPPLIERS OF SOLAR CELL
• SUPPLIERS OF EVA ENCAPSULATE
• SUPPLIERS OF ALUMINIUM FRAMER
• SUPPLIERS OF JUNCTION BOX
• SUPPLIERS OF SILICON GEL
• SUPPLIERS OF THERMO PLASTIC BACK SHEET
• MACHINERY SUPPLIERS COMPELETE PRODUCTION PLANT
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• MACHINERY PHOTOGRAPHS
• AUTOMATIC GLASS LOADING
• AUTOMATIC ENCAPSULANT CUTTING AND LOADING
• AUTOMATIC TEMPLATE LOADING
• INSPECTION TABLE
• TABBER AND STRINGER MTS-3000
• MIRROR INSPECTION TABLE
• AUTOMATIC BUSSING IC100 (3 HEADS)
• INTERCONNECTION CHECKING + LABEL PLACING
• AUTOMATIC FOIL CUTTING AND LOADING
• BUFFER
• LAMINATOR
• AUTOMATIC EDGE TRIMMING
• AUTOMATIC OPTICAL INSPECTION
• AUTOMATIC FRAMING UNIT
• JBOX WORKING TABLES
• JBOX POTTING DISPENSING MACHINE
• JBOX SILICONE DISPENSING MACHINE
• CURING LINE
• MODULE TESTING STATION
• AUTOMATIC MODULE SORTING
• AUTOMATIC GLASS LOADING
• AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
• AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
• CELL TESTER
• PRODUCT PHOTOGRAPHS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)