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NREL study highlights key strategies for affordable solar PV modules


Researchers at the US Department of Energy's National Renewable Energy Laboratory (NREL) have highlighted that enhancing the efficiency of solar modules and expanding manufacturing capacity are complementary approaches to reducing the costs of metal halide perovskite/silicon tandem solar modules. According to the researchers, the effectiveness of each cost-reduction strategy depends on a manufacturer’s ability to scale up operations and improve the performance of the modules.

Advantages of tandem modules over traditional silicon-based modules


Currently, most photovoltaic (PV) modules are based on single-junction silicon solar cells. However, by pairing silicon with another material such as metal halide perovskites (MHPs) to create a tandem, manufacturers can produce solar modules capable of converting more sunlight into electricity than traditional silicon-based modules. While this tandem technology is still in its early stages, several approaches to integrating MHPs and silicon are being explored, with many uncertainties surrounding the cost and performance of such modules. To better understand these variables, the NREL researchers developed a manufacturing cost model that combines laboratory processes with existing equipment and supply chains to assess different potential approaches at scale.

The study examined various methods for constructing tandem modules, focusing on factors that influence manufacturing costs, including the materials used to fabricate the device layers, production equipment, factory location, and other considerations. The researchers found that two main factors had the most significant impact on manufacturing costs: factory throughput and module efficiency.

Jacob Cordell, lead author of the paper titled "Technoeconomic Analysis of Perovskite/Silicon Tandem Solar Modules," published in the journal Joule, explained that one key takeaway is the value of improving module efficiency. "A 2.5% absolute efficiency gain in a module provides the same reduction in cost per nameplate capacity as doubling the size of your factory," Cordell said.

The researchers used the Detailed Cost Analysis Model (DCAM), now publicly available, to test different scenarios, such as the effects of factory location and manufacturing incentives on costs. This model offers companies and researchers a baseline tool to investigate how changes in processes and materials could impact costs. However, it does not address the energy production or lifespan of these modules, areas that are still under active research.

By using a baseline model, where manufacturers produce 25%-efficient modules in the United States at an annual capacity of 3 gigawatts, the study compared the effects of efficiency improvements and manufacturing output on module costs. This demonstrated the potential for research to enhance device efficiency and reduce costs per watt.

Many factors will continue to evolve in the pursuit of achieving the necessary efficiency and durability levels for commercially viable photovoltaic modules. For tandem modules to be competitive with other solar technologies, they must achieve an efficiency of at least 25%. The next steps in the commercialization of perovskite/silicon tandem modules will focus on improving the technology’s reliability in the field, scaling up high-efficiency devices to full module sizes, and maintaining optimal performance.

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