Periodic Reporting for period 1 - HIPERION (HYBRID PHOTOVOLTAICS FOR EFFICIENCY RECORD USING INTEGRATED OPTICAL TECHNOLOGY)
Reporting period: 2019-09-01 to 2020-11-30
Resulting in unique highly efficient solar modules and providing absolute record of energy generation per m2, with up to 50% gain in Central Europe and even 80% in Southern Europe.
Hence, HIPERION consortium proposes a plan to develop tailored assembly techniques, build a pilot production line and perform qualification tests from relevant norms. The first phase will mainly be dedicated to product industrialisation and assembly equipment construction, leading to the pilot line installation. The second phase will be dedicated to the production of a first series of modules, their extensive testing and monitoring on commercial pilot sites and planning the production scale-up. The target market segment is expected to be 1.25 GWp/yr but the production ramp-up to 1.25 FW should take at least 5 years.
HIPERION will demonstrate at pilot-line level the assembly of these high efficiency modules, while several commercial pilot sites across Europe and qualification tests will further validate the performance and reliability. Also, how the technology can be industrialised for mass production, enabling its integration by manufacturers into their existing production lines.
WP2 – Hybrid Module design optimization for performance, costs and reliability (INSO): GEN1 module design has been finalised and multiple modules (20+) have been built. Modules were installed at various locations (UPM, FRAU & INSO) for performance and reliability measurements. First key changes for GEN2 have been identified and are being discussed with partners and will be introduced in the coming weeks and months. The redesign has started on the optical layer with a focus on reliability and performance while keeping the ease-of-manufacturing in mind.
WP3 – Multi-junctions micro-cell receiver, test and board assembly (X-C): A cell release process for MTP was developed with photomasks ready to begin processing GEN1 COIs as described in D3.1. GEN1 COIs were manufactured using cells from Azurspace and wire-bonding. Additionally, a robust assembly process was developed, with 600 transparent boards printed by CSEM, and more than 400 boards assembled by Argotech which were used for reliability and assembly tests. A techno-economic analysis of COIs for high volume production was performed and compared with existing COI process.
WP4 – Module – assembly method and tests (MASS): Steps for the manufacture of GEN0 have been defined, (see D4.1) to later define the necessary steps for the manufacture of GEN1.2. The way of manufacturing the cells board assembly has been redefined, changing the pick place type for a laminate. For the lenses assembly, a series of improvements have been seen that are being implemented and validated for the GEN 2 design. In addition, within WP4 it is working on the design / manufacture of the framing machine, In-line and end-of-line test equipment.
WP5 – Pilot production line installation, hosting and operations (CSEM): WP5 is to build and operate a pilot production line hosted at CSEM, based on the materials, equipment and processes developed in WP2, WP3 and WP4, to demonstrate the new generation breakthrough technology developed in HIPERION in pilot-line environment, which include setting-up pilot-line to host the pilot-production equipment, coordination of the supply chain of consumables and products in collaboration with all partners, WPs and external suppliers. Operate the pilot-line and deliver first series of assembled modules, demonstrating performance, throughput, and providing modules for reliability qualifications (WP6) and in-field testing (WP7).
WP6 – Modules certification, pilot and reliability tests (UPM): 2 most important standard norms of PV technology, design qualification of the product and the power rating of a module have been addressed: a measurement procedure to determine the nominal power of hybrid CPV/PV modules has been defined, and a proposal for the quality assurance tests and the type approval of hybrid modules has been completed.
WP7 – Blueprint evaluation (3S): WP7 assessed early on what would be the LCA, LCOE and IRR of Gen1.2 so that such data could be used for decision making during the development phase. LCOE and IRR model was developed and the first calculations showed that space constraint applications might give an advantage to INSO modules when compared to competitors. LCA results showed that the Pmma used for the top glass assembly represented most almost half of the environmental load of the module. Preliminary results on climate change impact per KWh of Gen1.2 look promising with values between 9 to 14 g CO2-eq/kWh.
WP8 – Dissemination, Communication and Exploitation (L-UP): Dissemination and communication plan defined and regular monitoring of all dissemination and exploitation activities: 14 dissemination events, 54 mass media articles and press releases published worldwide, project corporate identity defined, project public website released online with regular updates and news, project social network pages set and regularly updated with news and videos.
WP9 – Ethics requirements (CSEM): Ensure compliance with the 'ethics requirements' set by the EC. The ethical and gender issues are regular monitored.
• WP3: Demonstrated a robust manufacturing process that ensures 1mm2 space-grade solar cells and SOE are assembled on a PV backplane within required alignment tolerance; cost competitive for high volume production.
• WP4: As a new process, strong and usable points have been detected and weak points to avoid in future assemblies have also been detected and adhesive application techniques.
• WP5: Demonstrate the pilot production and transfer the know-how and product from laboratory to industry. Upscaling the product from GEN0 to GEN2 and optimize the whole product chain at lower cost. Provide a training base and make a study of learning curve, collect product experience for mass production. Demonstrate small scaling production and lock the interest of potential investors, and a novel technology made in Europe and differentiate with recent commercial PV product.
• WP6: Develop international standard norms for hybrid CPV/PV modules.
• WP7: Show potential applications of the INSO module, help choosing BOM material based on environmental load and defining at an early stage the expected climate change impact of an INSO module.