Detailed Project Report on solar module manufacturing unit (solar energy output)

SOLAR MODULE MANUFACTURING UNIT 

(SOLAR ENERGY OUTPUT)

[CODE NO.4137]  

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.

Cells: Semiconductor device that converts sunlight into direct current (DC) electricity.

Modules: PV modules consist of PV cell circuits sealed in an environmentally protective laminate and are the fundamental building block of PV systems.

Panels: PV panels include one or more PV modules assembled as a pre-wired, field-installable unit.

Array: A PV array is the complete power-generating unit, consisting of any number of PV modules and panels.

Photovoltaic Cell

A single PV cell is a thin semiconductor wafer made of two layers generally made of highly purified silicon (PV cells can be made of many different semiconductors but crystalline silicon is the most widely used). The layers have been doped with boron on one side and phosphorous on the other side, producing surplus of electrons on one side and a deficit of electrons on the other side. 

When the wafer is bombarded by sunlight, photons in the sunlight knock off some of excess electrons, this makes a voltage difference between the two sides as the excess electrons try to move to the deficit side.

In silicon this voltage is .5 volt. Metallic contacts are made to both sides of the semiconductor. With an external circuit attached to the contacts, the electrons can get back to where they came from and current flows through the circuit. This PV cell has no storage capacity, it simply acts as an electron pump.

The amount of current is determined by the number of electrons that the solar photons knock off. Bigger cells, more efficient cells, or cells exposed to more intense sunlight will deliver more electrons.

Photovoltaic Modules

A PV module consists of many PV cells wired in parallel to increase current and in series to produce a higher voltage. 36 cell modules are the industry standard for large power production. 

The module is encapsulated with tempered glass (or some other transparent material) on the front surface, and with a protective and waterproof material on the back surface. The edges are sealed for weatherproofing, and there is often an aluminum frame holding everything together in a mountable unit. In the back of the module there is a junction box, or wire leads, providing electrical connections.

There are currently four commercial production technologies for PV Modules:

Single Crystalline

This is the oldest and more expensive production technique, but it's also the most efficient sunlight conversion technology available. Module efficiency averages about 10% to 12%*

Polycrystalline or Multicrystalline

This has a slightly lower conversion efficiency compared to single crystalline but manufacturing costs are also lower. Module efficiency averages about 10% to 11%*

String Ribbon

This is a refinement of polycrystalline production, there is less work in production so costs are even lower. Module efficiency averages 7% to 8%*

Amorphous or Thin Film

Silicon material is vaporized and deposited on glass or stainless steel. The cost is lower than any other method. Module efficiency averages 5% to 7%* 

*Check with manufacturer for module's accurate conversion efficiency.

Photovoltaic Panels

PV panels include one or more PV modules assembled as a pre-wired, field-installable unit. The modular design of PV panels allows systems to grow as needs change. Modules of different manufacture can be intermixed without any problem, as long as all the modules have rated voltage output within 1.0 volt difference. 

Photovoltaic Array

A PV Array consists of a number of individual PV modules or panels that have been wired together in a series and/or parallel to deliver the voltage and amperage a particular system requires. An array can be as small as a single pair of modules, or large enough to cover acres. 

12 volt module is the industry standard for battery charging. Systems processing up to about 2000 watt-hours should be fine at 12 volts. Systems processing 2000 - 7000 watt-hours will function better at 24 volt. Systems running more than 7000 watt-hours should probably be running at 48 volts.

COST ESTIMATION

Plant Capacity                            200 MW/Day  

Land & Building (800 sq.mt.)  Rs. 81.07 Cr    

Plant & Machinery                       Rs. 336 Cr 

Working Capital for 1 Month    Rs. 53 Lac  

Total Capital Investment            Rs. 500.26 Cr 

• INTRODUCTION
• CELLS MODULES AND ARRAYS
• PHOTOVOLTAIC CELLS, MODULES, PANELS AND ARRAYS.
• PHOTOVOLTAIC CELL
• PHOTOVOLTAIC MODULES
• SINGLE CRYSTALLINE
• POLYCRYSTALLINE OR MULTICRYSTALLINE
• STRING RIBBON
• AMORPHOUS OR THIN FILM
• PHOTOVOLTAIC PANELS
• PHOTOVOLTAIC ARRAY
• PROJECT LOCATION- KADAPA DISTRICT
• MAP
• CLIMATE
• TRANSPORT
• KADAPA AIRPORT TERMINAL
• ROADWAYS
• RAILWAYS
• AIRWAYS
• HISTORY OF PHOTOVOLTIC CELLS
• TYPES OF PV MODULE
• CRYSTALLINE SILICON PV MODULE
• (I) SINGLE CRYSTALINE (MONO-CRYSTALLINE)
• CONSTRUCTION
• TECHNICAL SPECIFICATION
• ADVANTAGES OF MONOCRYSTALLINE PV MODULE
• LONGEVITY
• DISADVANTAGES
• APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
• (II) 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:
• CONFIGURED SOLAR ELECTRIC 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
• FIGURE :- PV CELL POWER OUTPUT AS A FUNCTION OF VOLTAGE.
• EFFECT OF LIGHT INTENSITY
• CONCENTRATORS
• EQUATION BELOW;
• LOW LIGHT INTENSITY
• LINE CAPACITY
• SOLAR PV MODULE SPECIFICATION
• (A) MECHANICAL SPECIFICATION
• (B) ELECTRICAL SPECIFICATION
• SOLAR SYSTEM TYPICAL AND MINIMUM SITE REQUIREMENTS
• MINIMUM SUNLIGHT REQUIREMENTS FOR SOLAR SYSTEMS
• THE BOTTOM LINE IS, EVEN SCATTERED SUNLIGHT CAN PROVIDE SOLAR POWER. THE KEY QUESTION THEN, BECOME:
• HOW MUCH SURFACE AREA WILL BE REQUIRED IN ORDER TO GENERATE    
• THE DESIRED AMOUNT OF POWER?
• WILL THAT BE AVAILABLE WITHIN THE PROPOSED SOLAR SYSTEM SITE?
• WILL A SYSTEM OF THE REQUIRED SURFACE BE BE FINANCIALLY VIABLE, 
•    TO COVER THE COSTS INITIALLY AND TO RECOUP THAT INVESTMENT 
•    OVER TIME?
• PLANNING PERMISSIONS AND INSPECTIONS
• THERE ARE TWO FUNDAMENTAL ISSUES TO BE ADDRESSED HERE AT 
•   HIGH LEVEL:
• THE FOLLOWING LIST IS REPRESENTATIVE OF THE AREAS WHERE REQUIREMENTS WILL NEED TO BE SATISFIED:
• STRUCTURAL AND MECHANICAL STABILITY
• FIRE SAFETY
• ENVIRONMENT REQUIREMENTS (HYGIENE, HEALTH & THE ENVIRONMENT)
• SAFETY IN USE
• NOISE LEVELS AND PROTECTION AGAINST NOISE (IF ONLY DURING
•    INSTALLATION)
• ENERGY ECONOMY AND HEAT RETENTION
• SUSTAINABLE USE OF NATURAL RESOURCES
• SOLAR SYSTEM REQUIRED COMPONENTS
• AT THE SIMPLEST LEVEL, A SOLAR SYSTEM REQUIRES:
• CONNECTING TO YOUR LOCAL POWER GRID
• SOLAR SYSTEM TYPICAL REQUIREMENTS
• THEREFORE, FOR THE PURPOSES OF GENERAL GUIDANCE, 
•    A TYPICAL DOMESTIC ROOFTOP SYSTEM CONSISTS OF:
• 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
• EXAMPLES OF SOME APPLICATIONS OF PHOTOVOLTAICS    
•  ARE THE FOLLOWING:
• AGRICULTURE
• INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES
• LIGHTING OF STREETS, GARDENS AND PUBLIC TRANSPORTATION STOPS STREET SIGNALLING.
• HEALTH
• RESIDENTIAL
• B.I.S. SPECIFICATION
• 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 & 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)
• 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
• GROWING NUMBER OF UTILITY SCALE SOLAR PROJECTS 
•     WILL AUGMENT THE MARKET GROWTH
• PV PRODUCTION LINE
• M-01 AUTOMATIC GLASS LOADING
• M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
• FUNCTION:
• DESCRIPTION:
• M-03 AUTOMATIC TEMPLATE LOADING
• M-04 INSPECTION TABLE
• M-05 TABBER AND STRINGER MTS-3000
• HIGHLIGHTS:
• MAIN FEATURES:
• LIST OF EQUIPMENT INCLUDED:
• M-06 LAY-UP SYSTEM
• M-07 MIRROR INSPECTION TABLE
• M-08 AUTOMATIC BUSSING IC100 (3 HEADS
• M-9 INTERCONNECTION CHECKING + LABEL PLACING
• M-10 EL INSPECTION
• M-11 AUTOMATIC FOIL CUTTING AND LOADING
• M-12 BUFFER
• M-13 LAMINATOR
• M-14 AUTOMATIC EDGE TRIMMING
• M15 AUTOMATIC OPTICAL INSPECTION
• M-16 AUTOMATIC FRAMING UNIT
• AUTO FRAME FEEDER (OPTIONAL):
• M-17 JBOX WORKING TABLES
• M-18 AUTOMATIC JBOX POTTING MACHINE
• M-19 JBOX POTTING DISPENSING MACHINE
• M-20 JBOX SILICONE DISPENSING MACHINE
• M-21 CURING LINE
• M-22 MODULE TESTING STATION
• M-23 AUTOMATIC MODULE SORTING
• M-24 AUTOMATIC GLASS LOADING
• M-25 SECOND GLASS LOADING
• M-26 AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
• M-27 AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
• ACCESSORIES
• A-01 CELL TESTER
• 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 TEMPERED GLASS
• 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)