Detailed Project Report on solar module manufacturing unit

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SOLAR MODULE MANUFACTURING UNIT

[CODE NO.3990]

Brief Overview

The thin silicon disks called photovoltaic solar cells are known to convert sunlight into electricity. These are known to act as efficient energy sources for various uses such as calculators and other devices used for telecommunication, pumping, lighting, refrigeration, roof top panels, power satellites, to provide electricity to power plants and miscellaneous other uses. Let us have a look at the solar module / panel manufacturing process.

The Manufacturing Process of Solar Modules

After production of the solar cells, they are placed as electrical contacts between the cells. Thereafter, they are wired and arrayed subsequently. The solar cells are then sealed into ethylene vinyl acetate. Then, they are framed and sealed with silicon glue. Subsequently, they are covered with Mylar back on the backside and a glass plate on the front – termed as ‘lamination’. This step is indeed considered to be utmost important in the process of solar module manufacturing. This structure is then known to be supported with frames made up of aluminum. The figure below depicts the precise steps in solar module manufacturing process.

It is also important to have an appropriate power output check. A testing procedure needs to be done to ensure the power output.

The testing procedures include the flash test that measures voltage of open circuit (VOC), current at maximum power point, short-circuit current, voltage at maximum power point (VMP), the fill factor (FF) as well as the maximum power. Standard testing conditions are always put forth for the measurement of the parameters of the modules.

The standard testing conditions correspond to the irradiance and spectrum of sunlight incident on a clear day with the sun at a specific angle above the horizon. The solar cell manufacturing processes take into consideration the quality control processes. This is because the discrepancy in the various factors and processes can adversely affect the cell efficiency. It is important to find various ways to improve the efficiency and lifetime of the solar cells. It is normally observed that the silicon is tested much for crustal orientation, resistivity and purity at the same time. The presence of oxygen and carbon is also observed much by the manufacturers. The silicon disks are observed and inspected much for bending, flaking, damage, polishing, sawing, etching an dother factors.

It is important to monitor the temperature, pressure, speed and quantities of dopants during the entire silicon disk manufacturing process. It is important that the semiconductors undergo various important electrical tests to see that appropriate standards are maintained for the current, voltage and resistance. The dangerously high voltages of the cells are avoided by the use of shunt diodes.

The final step involves field site testing wherein the finished modules are placed where they are actually supposed to be used. The efficiency of the solar cells can then be determined under ambient conditions. Thus, we have hereby understood the solar module/panel manufacturing process in detail, so as to always run them efficiently and productively.

COST ESTIMATION

Plant Capacity 0.75 MW/Day

Land & Building (12000 sq.mt.) Rs. 14.47 Cr

Plant & Machinery Rs. 3.45 Cr

Working Capital for 1 Month Rs. 35.07 Cr

Total Capital Investment Rs. 80.70 Cr

Rate of Return 57%

Break Even Point 31%

INTRODUCTION

CELLS MODULES AND ARRAYS

PHOTOVOLTAIC CELL

PHOTOVOLTAIC MODULES

SINGLE CRYSTALLINE

STRING RIBBON

PHOTOVOLTAIC PANELS

PHOTOVOLTAIC ARRAY

PROJECT LOCATION-AHMEDABAD (GUJRAT)

WEATHER

CITY MAP OF AHMEDABAD

TRANSPORTATION

BY AIR:-

BY ROAD:

BY TRAIN:

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

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

LOW LIGHT INTENSITY

LINE CAPACITY

TABBER AND STRINGERS: 2

LAY-UP: 2

INTERCONNECTION 1

LAMINATORS: 2

SOLAR PV MODULE SPECIFICATION

(B) ELECTRICAL SPECIFICATION

DIFFERENCE BETWEEN STC AND NOCT:

STC (STANDARD TEST CONDITIONS):

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:

INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES

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 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)

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

M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING

M-03 AUTOMATIC TEMPLATE LOADING

M-04 INSPECTION TABLE

M-05 TABBER AND STRINGER MTS-3000

M-06 LAY-UP SYSTEM

M-07 MIRROR INSPECTION TABLE

M-08 AUTOMATIC BUSSING IC100 (3 HEADS

M-09 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

M-15 AUTOMATIC OPTICAL INSPECTION

M-16 AUTOMATIC FRAMING UNIT

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

FUNCTION:

CHARACTERISTICS:

ADVANTAGES:

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

J BOX WORKING TABLES

J BOX POTTING DISPENSING MACHINE

J BOX 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)

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