Creating electricity by reducing cost, Payback time and Carbon footprint - An exploitation of a novel method into manufacturing c-Si PV solar Cells
Lead Research Organisation:
De Montfort University
Department Name: Engineering
Abstract
This project will develop and demonstrate a new method of making polycrystalline silicon (poly-Si) deposited on plastic and
glass subsrates for photovoltaic (PV) solar cell application. Poly-Si is a versatile material that is used extensively for energy
generation in solar panels. Current methods for producing poly-Si involve high temperatures above 600 degrees
centigrade, so it is usually deposited on glass or metal substrates and involves energy expensive costs (57 %) for the
extraction, purification of polysilcon for PV. This new method, using plasma enhanced chemical vapour deposition, will
carry out at temperatures below 350 degrees, which is within the range of some thermoplastic polymers. The process has
already been demonstrated at laboratory scale within the Emerging Technology Research Centre at De Montfort University
and a patent application has been granted . Moreover, it will reduce significantly costs and energy usage during
manufacture of devices, and precursor to the UK PV manufacturing industires. This project will fully optimise the process
granular crystal size of silicon with consistent quality for Photovaoltaic solar cell application.
glass subsrates for photovoltaic (PV) solar cell application. Poly-Si is a versatile material that is used extensively for energy
generation in solar panels. Current methods for producing poly-Si involve high temperatures above 600 degrees
centigrade, so it is usually deposited on glass or metal substrates and involves energy expensive costs (57 %) for the
extraction, purification of polysilcon for PV. This new method, using plasma enhanced chemical vapour deposition, will
carry out at temperatures below 350 degrees, which is within the range of some thermoplastic polymers. The process has
already been demonstrated at laboratory scale within the Emerging Technology Research Centre at De Montfort University
and a patent application has been granted . Moreover, it will reduce significantly costs and energy usage during
manufacture of devices, and precursor to the UK PV manufacturing industires. This project will fully optimise the process
granular crystal size of silicon with consistent quality for Photovaoltaic solar cell application.
Planned Impact
In lieu of these anticipated economies of scale, one of the major drivers for PV technologies achieving these sustainability
benefits is the need to drastically reduce electricity generation costs. Therefore, issues such as energy requirement,
material usage and manufacturing time are fundamental to achieving these reductions. This project would result in at least
a 50% reduction in energy usage during poly-Si growth. There would be an even greater reduction in manufacturing time
as the film would not require extended annealing at high temperatures (usually a number of hours), and the required
thickness could be achieved in a relatively shorter time; which would be the case for all the silicon layers forming each cell
structure. There is the additional benefit that the total material requirements for this process are much lower than those of
c-Si cells. All of these factors address the touchstone issues for the viability of widespread PV deployment. And the
methodologies of the process itself would ensure rapid integration into present manufacturing procedures.
benefits is the need to drastically reduce electricity generation costs. Therefore, issues such as energy requirement,
material usage and manufacturing time are fundamental to achieving these reductions. This project would result in at least
a 50% reduction in energy usage during poly-Si growth. There would be an even greater reduction in manufacturing time
as the film would not require extended annealing at high temperatures (usually a number of hours), and the required
thickness could be achieved in a relatively shorter time; which would be the case for all the silicon layers forming each cell
structure. There is the additional benefit that the total material requirements for this process are much lower than those of
c-Si cells. All of these factors address the touchstone issues for the viability of widespread PV deployment. And the
methodologies of the process itself would ensure rapid integration into present manufacturing procedures.
Publications
Gupta R
(2022)
Smart and Flexible Energy Devices
Nama Manjunatha K
(2020)
Comparative Study of Silicon Nanowires Grown From Ga, In, Sn, and Bi for Energy Harvesting
in IEEE Journal of Photovoltaics
Nama Manjunatha K
(2019)
Carrier selective metal-oxides for self-doped silicon nanowire solar cells
in Applied Surface Science
Nama Manjunatha K
(2019)
Wire-bar coating of doped Nickle oxide thin films from metal organic compounds
in Applied Surface Science
Paul F
(2020)
Single step ohmic contact for heavily doped n-type silicon
in Applied Surface Science
| Title | iMatSci |
| Description | Novel Fabrication process used in this research work that is based on DMU patent process is explained to public or research community with the step by step guide highlighted in a movie along with short video clips. Along with the movie that was designed, few demonstration kits were made available showing all the steps involved in depositing silicon nanostructures. A proof of concept lab scale working solar cell was made available. |
| Type Of Art | Film/Video/Animation |
| Year Produced | 2016 |
| Impact | First proof of demonstration of a practical application of silicon nanostructures grown by the process, developed in the project, is shown for photovoltaic solar cell. |
| Description | The most important innovation from this feasibility project was a set of working solar cells based on the new technology. These cells had, in the view of the authors, an acceptable efficiency for such an early stage PV technology achieving 6-8% on glass substrates and 1.2% on plastic substrates. The structure of the PV, being based on a silicon nanowire structure, has generated significant interest from, primarily academic, but commercial organisations too. The core technology to be developed in the RA project is a new form of solar cell using Si nanowires (SiNWs). The novelty being the method in which these Si nanowires are grown at low temperature - thereby enabling growth at lower cost on a wider range of substrates |
| Exploitation Route | Our plans though - specifically PEL and DMU - are focussed on gaining additional funding to be able to answer the remaining technical questions and taking ideas develop during the project forward. |
| Sectors | Chemicals,Digital/Communication/Information Technologies (including Software),Electronics,Energy,Manufacturing, including Industrial Biotechology |
| Description | Environment Impact:: The vast expansion of semiconductor industries in all sectors of the economy contributes to worrying effects on the environment: pollution in manufacturing plants; depletion of raw materials; electricity consumption during use; and accumulation of electronic waste, amongst others. Semiconductor Industries use a large amounts of energy, water (for processing and controlling the temperature of temperature furnaces) and many toxic chemicals, all of which can harm the environment. In order to achieve such silicon nano-structures at low-temperatures, a pioneering manufacturing process was developed (referred to as the RA process - after the ancient Egyptian Sun God, Ra), has been further investigated from the uses of energy view point. A detailed measurements were carried on the energy used for the Ra process. The energy required to produce poly-crystalline silicon by conventional techniques is 407 kW-hrs/m2 but the Ra process uses only 127 kW-hrs/m2. Thus, saving 280 kW-hrs/m2 of energy. RAing is a "green" process capable of reducing the carbon footprint of crystalline silicon nano-structure production; the economics of device manufacture also improves under this process. The Ra process can certainly provide less uses of energy required to produce poly-crystalline silicon, and may retard the fast depletion of raw materials and the mining impact on the environment (special Sn, In - which are commonly used in VLS process). The impact of this research has been to (so far): • Energy Related Devices: Photovoltaic Solar Cells, Li-Ions batteries. • Environmental impact: Reduction in energy uses (Energy required to produce poly-crystalline silicon by conventional technique is 407 kW-hrs/m2 but our process method uses only 127 kW-hrs/m2. Thus, saving of 280 kW-hrs/m2 of energy required to produce thin film for photovoltaic solar cell applications. • Change of behaviour/practises: Encouragement to look for the energy saving process (based on the feedback data from the focussed group. |
| First Year Of Impact | 2019 |
| Sector | Education,Energy,Environment,Other |
| Impact Types | Cultural,Societal |
| Description | Impact on promoting education for aspiring students from developing countries |
| Geographic Reach | Multiple continents/international |
| Policy Influence Type | Influenced training of practitioners or researchers |
| Impact | Several students around the globe (Africa, India and Saudi Arabia) are provided an opportunity to join and carry out research study as part of PhD degree at De Montfort University. This not only promotes education for students from developing countries where facilities are limited but also exposing them to advanced UK based education system. This significantly demonstrates that diversity promoted in the UK. This research has provided an opportunity to several students to carry out dissertation as part of their MSc degree programme which has given exposure to research facilities and research embedded teaching. We have seen providing such opportunity to students has impacted them to further progress their studies as part of PhD program. In few occasions, we have seen students joining research-oriented companies. |
| Description | eFutures 2.0: Addressing Future Challenges |
| Amount | £484,102 (GBP) |
| Funding ID | EP/S032045/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 05/2019 |
| End | 05/2023 |
| Title | Ra process is being used in EMTERC, extensively. |
| Description | This is a non-biological research process. Extensively used by research and postgraduate students for research projects. The patent, GB2482915 - A low temperature method for the production of polycrystalline silicon, aligned silicon columns and silicon nanowires (Date Lodged: 20 August 2010, Granted on 5/2/2013), was exploited further during the tenure of this project and applied to new applications. |
| Type Of Material | Improvements to research infrastructure |
| Year Produced | 2017 |
| Provided To Others? | No |
| Impact | There is already demonstration of environmental impact. However, both economic and societal impact are being considered. |
| Title | Growth of Silicon nanostructures on flexible transparent plastic substrates |
| Description | The novel growth process is established with certain pre-treatment processes to grow/deposit silicon nanostructures on a plastic substrate that adhere strongly to the substrate when it is held flat, bent and stretched. |
| Type Of Material | Database/Collection of data |
| Year Produced | 2017 |
| Provided To Others? | No |
| Impact | This may lead towards flexible silicon-based solar cells on extremely thin substrates ( <25 microns) |
| Description | Printed Electronics Limited |
| Organisation | Printed Electronics Ltd |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | • Organise Quarterly Consortium Meetings • Report project progress against objectives • Ensure quarterly claims are prepared for each consortium member with forecasts • Deposition of catalyst layer on various substrates and analysis of deposited layers • Deposition of silicon nano-structures using PECVD system, and analysis of deposited films by SEM, RAMAN, UV-VIS, XRD, FTIR, etc. • Fabrication of photovoltaic solar cells and their analysis. |
| Collaborator Contribution | Printed Electronics Limited (PEL) - to use printing methods to provide a low cost deposition process for the liquid materials used for the silicon nanowire precursors, in order to determine whether processes could be scaled using existing printing and known roll-to-roll (R2R) methods. |
| Impact | PEL - have developed new ink formulations that enable the pre-cursors for silicon nanowires to be deposited at low cost using an inkjet process. The process is non-contact and so lends itself to thin polymeric substrates as well as glass and other rigid materials. |
| Start Year | 2016 |
| Description | Victrex plc |
| Organisation | Victrex |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | • Organise Quarterly Consortium Meetings • Report project progress against objectives • Ensure quarterly claims are prepared for each consortium member with forecasts • Deposition of MOs on various substrates and analysis of deposited layers • Deposition of silicon nano-structures using PECVD system, and analysis of deposited films by SEM, RAMAN, UV-VIS, XRD, FTIR, etc. • Fabrication of photovoltaic solar cells and their analysis on PEEK substrates provided by Victrex Plc. |
| Collaborator Contribution | VICTREX - have provided substrates from their range of PEEK materials and have developed a deeper understanding of when/where such materials can be used in these processes. |
| Impact | The role of Victrex in this project was to understand the suitability of a new high dimensional stability PEEK film (Bi-Axially orientated) to high temperature processes such as the deposition of silicon photovoltaic cells. This was partially achieved in that the deposition of PV silicon was achieved towards the end of the project. |
| Start Year | 2016 |
| Title | Materials grown by plasma-enhanced chemical vapour deposition |
| Description | A method of growing a semiconductive material using plasma-enhanced chemical vapour deposition, the method comprising: providing a seeding layer to a reactor, wherein the seeding layer comprises a seeding precursor, wherein the seeding precursor comprises a coordination complex; and exposing the seeding layer to a plasma phase of at least one gaseous precursor, at a temperature above a cracking temperature of the seeding precursor, to grow the material. |
| IP Reference | GB2008726.8 |
| Protection | Patent application published |
| Year Protection Granted | 2020 |
| Licensed | No |
| Impact | We are exploring the ways to license the IP - no commercial impact so far. |
| Description | A Novel Silicon Manufacturing Method - a step towards NetZero |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Made connection with Make-UK |
| Year(s) Of Engagement Activity | 2022 |
| URL | https://www.advancedengineeringuk.com/guest/shashi-paul-university-of-montfort/ |
| Description | A focused group study on the benefit of low temperature Silicon manufacturing process |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Postgraduate students |
| Results and Impact | A focussed group study: We hope to train a new breed of scientist or scientist already working in semiconductor industries, one who knows how to design in environmental factors from the beginning and/or willing to change their behaviour/practises employed in the semiconductor industries. A focus group study was organised on the Ra process by giving a short presentation and the participants were then guided through a discussion by a moderator. At the end of the discussion, a feedback form was given to each participant and their responses were taken as Yes or No to the following questions: 1. Have you enjoyed coming to the presentation? (100 % said: YES) 2. Do you think that the Ra process is an energy saving process? ((100 % said: YES) 3. Do you think that the Ra process is an environmentally friendly process? ((100 % said: YES) 4. Are you inspired by the Ra process and will look for alternative energy saving processes in your own research field or fields? (100 % said: YES) 5. Now that you know about the benefits of the Ra process, are you interested in participating in research activities related to the Ra process at DMU. (100 % said: YES) 6. The cost of Photovoltaic solar deployment in the developing world is an issue. Do you think that Photovoltaic solar cells, based on the Ra process, can provide low cost photovoltaic solar cells to the developing world? (100 % said YES) 7. Any suggestions/Comments (some of the suggestions & comments taken from the feedback form are listed below): • "Low thermal budget is the best thing" • "The process incorporates the sustainability parameters which are the focus of the university" • "I think the process is highly promising due to largely cost reduction (Energy, materials and human" There were 7 participants. |
| Year(s) Of Engagement Activity | 2019 |
| Description | Demonstration on Photovoltaic Solar cells and research activities related to Ra process |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Schools |
| Results and Impact | The demonstration on photovoltaic related research activities was held during university open days. Both the potential applicants and parents participated in the demonstration. |
| Year(s) Of Engagement Activity | 2021,2022,2023 |
| Description | Doped and Un-doped Silicon Nanowires for Photovoltaic Applications |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Postgraduate students |
| Results and Impact | Given Invited talk on "Doped and Un-doped Silicon Nanowires for Photovoltaic Applications" as a more sustainable manufacturing process for solar cells. Doping from an appropriate metal catalyst has several advantages, such as; elimination of toxic gases, avoiding the complexity of counter-doping caused by the catalyst, reducing costs, and simplifying the optimisation process. More than 100 people across the world attend this talk that was organised as part of the International Conference on Soft Materials (ICSM 2020). Various undergraduate and postgraduate students asked many questions that further led to a discussion about how research should be carried out in a most sustainable process. |
| Year(s) Of Engagement Activity | 2020 |
| URL | http://smrsi.org/icsm2020/ |
| Description | Emerging Applications of Silicon Nano-structures |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Given a plenary talk on "Emerging Applications of Silicon Nano-structures" - attended by research active people from both academia and industries. |
| Year(s) Of Engagement Activity | 2018 |
| URL | https://www.icpam.ro/speaker/shashi-paul |
| Description | Growth of Silicon Nanostructures at low Temperature and their application in Energy related - Invited talk in Autumn School on Physics of Advanced Materials |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | The invited talk sparked further disscusion on the Ra process. |
| Year(s) Of Engagement Activity | 2022 |
| URL | https://icpam.ro/ |
| Description | LATE NEWS- HOT TOPIC in MRS-2020 Fall Meeting, Boston, USA |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Our research work was featured as LATE NEWS- HOT TOPIC in MRS-2020 Fall Meeting highlighted as most recent innovative findings in materials research. Inspired from this research work, similar approach in the characterisation is adopted by 10.1063/1.5086617 to understand if catalyst(metal) can act as dopant/electronic defects. |
| Year(s) Of Engagement Activity | 2020 |
| Description | Silicon photonics adoption in UK industry - impact by collaboration, participated and presented a poster. |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | A number of people from industries shown an interest in the work. We are now pursuing further links with the industries. |
| Year(s) Of Engagement Activity | 2017 |
| URL | http://www.photonex.org/conference/17/silicon.html |
| Description | Silicon: past, present and future- Plenary talk |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | A plenary talk was given by Prof. S Paul on "Silicon: past, present and future" in the 13th International Conference on Physics of Advanced Materials held at Hotel Eden Roc, Sant Feliu de Guixols, Spain, September 24-30, 2021, |
| Year(s) Of Engagement Activity | 2021 |
| Description | The Rushlight Summer Showcase, held at the Royal Geographical Society, London |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | The Rushlight Summer Showcase is THE marketplace that brings together over 250 cleantech developers and sustainable solution providers, active European investors & financiers, corporate venturers, government departments, consultants, intermediaries, advisers and businesses looking to source suppliers and partners for an improved level of sustainability in their supply chain and operations. |
| Year(s) Of Engagement Activity | 2017 |
| Description | Thin Film and Coating Technologies for Science & Industry meeting |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Plasma Enhanced Chemical Vapour Deposition of Silicon Nano-structures and their applications in Electronic and Energy related Devices, Thin Film and Coating Technologies for Science & Industry meeting, 11th October 2017 at Ricoh Arena, Coventry, UK. |
| Year(s) Of Engagement Activity | 2017 |
| Description | Unconventional Connections and Finovista |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Prof. S Paul was invited to submit information for Unconventional Connections and Finovista are scoping out for FCDO/DIT/Science and Innovation Network India the potential for UK companies and researchers to provide or develop solutions that could help Indian businesses reduce their carbon footprint. Following that, Prof. Paul was one of the panellist to speak carbon footprint related to semiconductor industries. T |
| Year(s) Of Engagement Activity | 2021 |
| Description | iMatSci |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | A novel method for Manufacturing of Crystalline Silicon structures - iMatSci Technology Pitch at Materials Research Society's Fall Meeting at Boston, USA(2016). MatSci Innovator Showcase provides a platform for technology leaders at universities, research labs and start-up companies to demonstrate the practical applications of innovative, materials-based technologies. The goal of this program is to convene innovators, industry leaders and investors in one location to spur collaboration that accelerates the adoption of new materials technologies for real-world applications. |
| Year(s) Of Engagement Activity | 2016 |