Detailed Project Report on manufacture of photovoltaic panels for solar power application

MANUFACTURE OF PHOTOVOLTAIC PANELS FOR SOLAR POWER APPLICATION
[CODE NO.3922]  


Solar Panels are in general Silicon made Rectangular Shaped Glass Covered Products which Produce Electricity when exposed to the Sun.These Panels produce Direct Current (DC) Electricity which has to be converted by a  Solar Inverter to Alternating Current (AC) Electricity to be used by Consumers

Solar PV panel refers to a panel designed to absorb the sun's rays as a source of energy for generating electricity

A photovoltaic (in short PV) module is a packaged, connect assembly of typically 6×10 solar cells. Solar Photovoltaic panels constitute the solar array of a photovoltaic system that generates and supplies solar electricity in commercial and residential applications. Each module is rated by its DC output power under standard test conditions, and typically ranges from 100 to 365 watts A single solar module can produce only a limited amount of power; most installations contain multiple modules. A photovoltaic system typically includes a panel or an array of solar modules, a solar inverter, and sometimes a battery and/or solar tracker and interconnection wiring.The price of solar power, together with batteries for storage, has continued to fall so that in many countries it is cheaper than ordinary fossil fuel electricity from the grid (there is "grid parity")., Solar panel refers to a panel designed to absorb the sun's rays as a source of energy for generating electricity or heating.A photovoltaic (PV) module is a packaged, connect assembly of typically 6×10 solar cells. Solar Photovoltaic panels constitute the solar array of a photovoltaic system that generates and supplies solar electricity in commercial and residential applications. Each module is rated by its DC output power under standard test conditions, and typically ranges from 100 to 365 watts


COST ESTIMATION


Plant Capacity                    97200 Per Year         
Land & Building (4000 sq.mt.)   Rs. 3.22  Cr                         
Plant & Machinery               Rs. 2.63  Cr                            
Working Capital for 2 Month     Rs. 9.98  Cr       
Total Capital Investment        Rs. 16.22 Cr
Rate of Return                    71%                   
Break Even Point             34%            


INTRODUCTION    
SOLAR CELL    
CONSTRUCTION OF SOLAR CELL    
WORKING PRINCIPLE OF SOLAR CELL    
SOLAR CELL MANUFACTURING TECHNOLOGY    
THIN FILM SOLAR CELL    
CRYSTALLINE SILICON SOLAR CELL    
SOLAR PHOTO VOLTAIC (SPV) MODULE    
SOLAR PV PANNEL    
SERIES IN THE MODULE    
RATINGS OF SOLAR MODULE    
V-I CHARACTERISTIC OF SOLAR MODULE    
SHORT CIRCUIT CURRENT OF PV MODULE    
THIS IS DENETED AS JSC.    
OPEN CIRCUIT VOLTAGE (VOC)    
MAXIMUM POWER POINT    
FILL FACTOR OF A SOLAR MODULE    
EFFICIENCY OF SOLAR MODULE    
NUMBER OF CELLS IN MODULE    
TECHNOLOGY OF SOLAR PV MODULE    
(A) FLAT PLATE TECHNOLOGY    
(1) CRYSTALLINE TECHNOLOGY    
(A) MONOCRYSTALLINE SILICON    
FIGURE BELOW DEPICTS THE MONOCRYSTALLINE CELL    
MONO CRYSTALLINE CELL    
(B) MULTICRYSTALLINE SILICON OR POLY CRYSTALINE CELL    
(2) THIN FILM TECHNOLOGY    
FIGURE BELOW DEPICTS THE THIN FILM CELL    
THIN FILM SOLAR CELL    
(A) AMORPHOUS SILICON THIN FILM TECHNOLOGY    
(B) CADMIUM TELLURIDE THIN FILM TECHNOLOGY    
(2) CONCENTRATED PHOTOVOLTAIC TECHNOLOGY    
FIGURE BELOW DEPICTS A CONCENTRATED PV MODULE.    
CONCENTRATED PV TECHNOLOGY    
TYPES OF SOLAR PV PANEL    
(A) CRYSTALLINE SILICON SOLAR PANEL    
SINGLE CRYSTALINE (MONO-CRYSTALLINE)    
POLY-CRYSTALLINE (MULTI CRYSTALLINE)    
(B) THIN FILM SOLAR PANEL (AMORPHOUS SOLAR PANELS)    
(A) AMORPHOUS SILICON THIN FILM TECHNOLOGY    
(B) CADMIUM TELLURIDE THIN FILM TECHNOLOGY    
ADVANTAGES OF PV PANNEL    
DISADVANTAGES OF PV PANNEL    
USES AND APPLICATION OF PV POWER PLANT    
EXAMPLES OF SOME APPLICATIONS OF PHOTOVOLTAICS
    ARE THE FOLLOWING:    
AGRICULTURE    
INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES    
HEALTH    
RESIDENTIAL    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART FOR SOLAR PANEL    
ASSYMBLING PROCESS OF SOLAR PANEL    
PLANT AND MACHINERY    
(1) CELL TESTER    
(2) TABBING & STRINGING MACHINE    
(3) LAYUP MACHINE    
(4) MODULE LAMINATOR    
(5) MODULE TESTER    
(6) LASER INSPECTION MACHINE    
MARKET POSITION    
INDIA – POTENTIAL    
ANNUAL INSOLATION    
GROWTH IN THE INDIAN SOLAR MODULE SEGMENT    
OPPORTUNITIES IN THE GLOBAL SOLAR MODULE SEGMENT    
DEMAND FOR SOLAR PV MODULES BY YEAR (GW)    
WHY SHOULD WE PRODUCE PV MODULES IN INDIA?    
ECONOMIC SENSE TO SET UP PV MODULE CAPACITY.    
REALISTIC INDIAN SOLAR ENERGY INSTALLATION TARGET.    
INDIA’S ATTRACTIVENESS IN PV MODULE MANUFACTURING.    
THE OTHER PLAYERS RANKED ABOVE INDIA ARE AS FOLLOWS:    
OPPORTUNITY LIES AHEAD.    
INDIA CAN BE A LEADER IN PV MODULE MANUFACTURING.    
PLANT LAYOUT    
SUPPLIERS OF PV SOLAR PV MODULE    
SUPPLIERS OF RAW MATERIALS    
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    
SUPPLIERS OF COMPELETE PRODUCTION PLANT FOR PV PANNEL    
SUPPLIERS OF COMPELETE PRODUCTION PLANT FOR PV PANNEL    
SUPPLIERS OF POWER TRANSFORMERS    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF PLATFORM WEIGHING MACHINE    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS    


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)