SOLAR CELL & MODULE MANUFACTURING (PRODUCTION CAPACITY:-500 MV)

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SOLAR CELL & MODULE MANUFACTURING (PRODUCTION CAPACITY:-500 MV)

[EIRI/EDPR/4805] J.C: 3026)

A solar cell (also known as a photovoltaic cell or PV cell) is defined as an electrical device that converts light energy into electrical energy through the photovoltaic effect. A solar cell is basically a p-n junction diode. Solar cells are a form of photoelectric cell, defined as a device whose electrical characteristics – such as current, voltage, or resistance – vary when exposed to light.

Individual solar cells can be combined to form modules commonly known as solar panels. The common single junction silicon solar cell can produce a maximum open-circuit voltage of approximately 0.5 to 0.6 volts. By itself this isn’t much – but remember these solar cells are tiny. When combined into a large solar panel, considerable amounts of renewable energy can be generated.

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.

COST ESTIMATION

Plant Capacity 5977 Pieces/Day

Land & Building (16000 sq.mt.) Rs. 9.80 Cr

Plant & Machinery Rs. 60.90 Cr

Working Capital for 1 Month Rs. 74.85 Cr

Total Capital Investment Rs. 148.80 Cr

Rate of Return 68%

Break Even Point 26%

CONTENT

INTRODUCTION
CELLS MODULES AND ARRAYS
PHOTOVOLTAIC CELL
PHOTOVOLTAIC MODULES
COMMERCIAL PRODUCTION TECHNOLOGIES FOR PV
SINGLE CRYSTALLINE
POLYCRYSTALLINE OR MULTICRYSTALLINE
AMORPHOUS OR THIN FILM
PHOTOVOLTAIC PANELS
PHOTOVOLTAIC ARRAY
PROJECT LOCATION
LUNAWADA
MAP
TRANSPORTATION
Near By major Cities
Near By Air Ports
Near By Tourist Places
Near By Local Cities
Near By Districts
Near By RailWay Station
HISTORY OF PHOTOVOLTIC CELLS
TYPES OF PV MODULE
CRYSTALLINE SILICON PV MODULE
SINGLE CRYSTALINE (MONO-CRYSTALLINE)
CONSTRUCTION
TECHNICAL SPECIFICATION
ADVANTAGES OF MONOCRYSTALLINE PV MODULE
DISADVANTAGES
APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
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
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
EFFECT OF LIGHT INTENSITY
CONCENTRATORS
LOW LIGHT INTENSITY
LINE CAPACITY
SOLAR PV MODULE SPECIFICATION
(A) MECHANICAL SPECIFICATION
1. Solar Cell Type
2. Cell Dimension (in inches/mm.)
3. Module Dimension (in inches/mm.)
4. Module Weight (in kgs./lbs.)
5. Glazing or front Glass
6. Frame
7. Output Cables
8. Junction Box
(B) ELECTRICAL SPECIFICATION
1. Peak Power (W)
2. Optimum operating Voltage
3. Optimum operating current
4. Open Circuit Voltage
5. Short Circuit Current
7. Module Efficiency
8. Operating Temperature
9. Max. Series Fuse Rating
10. Power Tolerance
11. Parameters defined under NOCT
12. Temperature Coefficients
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
Agriculture
Industry, Telecommunications & Public Services
Health
Residential
B.I.S. SPECIFICATION
HEADQUARTERS
SALES OUTLETS ADDRESS
TELEPHONE NO/FAX/E-MAIL
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)
MODULE ASSEMBLY STEPS
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
Function
Description
Main features
Features GLL0205-2
M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
Function
Description
Features FCM0304-2
M-03 AUTOMATIC TEMPLATE LOADING
Function
Description
Features FCM0305-1
M-04 INSPECTION TABLE
Function
Characteristics
Features ICB2205-1
Advantages
M-05 TABBER AND STRINGER MTS-3000
Function
Description
Highlights
Main Features
Cell parameters
Tabs
Strings
Tabbing & Stringing
Performance features
System dimensions
System control & software
LIST OF EQUIPMENT INCLUDED:
M-06 LAY-UP SYSTEM
Function
Highlights
Features LUS2200-1
M-07 MIRROR INSPECTION TABLE
Function
Characteristics
Features ICB2200-1
Advantages
M-08 AUTOMATIC BUSSING IC100 (3 HEADS
Function
Description
Advantages
Features ICB2001-1
M-9 INTERCONNECTION CHECKING + LABEL PLACING
Function
Characteristics
Features ICB2207-1
Advantages
M-10 EL INSPECTION
Function
Characteristics
Features EL MA
M-11 AUTOMATIC FOIL CUTTING AND LOADING
Function
Description
Features FCM0307-2
M-12 BUFFER
Function
Characteristics
Advantages
Features BUF3501-1
M-13 LAMINATOR
Function
Description
Advantages of our Laminators
Features LAM3024-1
M-14 AUTOMATIC EDGE TRIMMING
Function
Characteristics
Advantages
Process description
Features ETM3604-2
M15 AUTOMATIC OPTICAL INSPECTION
Function
Characteristics
Advantages
Features VT5007-1
Optical inspection
M-16 AUTOMATIC FRAMING UNIT
Function
Characteristics
Features FR4200-2
Auto frame feeder (OPTIONAL)
M-17 JBOX WORKING TABLES
Function
Characteristics
Advantages
M-18 AUTOMATIC JBOX POTTING MACHINE
Function
Characteristics
Features JBX3709-1
M-19 JBOX POTTING DISPENSING MACHINE
Function
Characteristics
Features JBX3707-1
M-20 JBOX SILICONE DISPENSING MACHINE
Function
Characteristics
Advantages
Features JBX3707-1
M-21 CURING LINE
Function
Characteristics
Advantages
Features CUR 6001-2
M-22 MODULE TESTING STATION
Function
Main characteristics
Features IVT5006-1 ENDEAS QUICKSUN 600
M-23 AUTOMATIC MODULE SORTING
Function
Advantages
Features SOR6102-1
M-24 AUTOMATIC GLASS LOADING
Function
Description
Main features
Features GLL0205-1
M-25 SECOND GLASS LOADING
Function
Characteristics
Advantages
Features SGL0206-1
M-26 AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
Function
Characteristics
Advantages
Features SOR6102-1
M-27 AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
Function
Highlights
Precious separation
Low consumption
Features: GDS 50
Offline Equipment Quantity
ACCESSORIES
A-01 CELL TESTER
Function
Characteristics
Advantages
Features CLT0102-1
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 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 ASSETS
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 (5-10 YEARS)

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