The development and demonstration of a unique low cost scalable PV technology for international development.

Lead Research Organisation: Newcastle University
Department Name: Sch of Engineering

Abstract

Big Solar Limited (BSL) is developing Power Roll (PR) that is a ground breaking, ultra-low cost and ultra-lightweight solar
photovoltaic (PV) solution. The design of PR represents a breakthrough in the challenge of generating renewable energy
at a cost cheaper than hydrocarbons and 40% lower than silicon PV. This is a disruptive technology with the potential to
transform the lives of 1.2 billion people without access to electricity as well helping the UK in delivering its carbon reduction
targets.
Sir Joseph Swan Centre for Energy Research at Newcastle University aims to deploy this ground-breaking solar PV in Sub-
Saharan Africa. A two stage deployment of first generation Power Roll product will address the needs of rural off-grid
communities in African markets. Many of these communities are still without electrical power and the limited Electric Power
Infrastructure within these countries offers a dim outlook for immediate delivery of grid-based power to these communities.
This makes off-grid electricity supply and storage solutions an invaluable transitional solution that could have an immediate
impact on the quality of life of these communities. The proposed deployment of first generation PV rolls will integrate a
small and subsequently medium size Power Roll to enable solar electricity generation aimed at operating portable or
irrigation water pumping duties, or the processing of harvested crops (for instance drying) to eliminate post-harvest food
losses which is of great concern and a major cause of hunger and poverty in SSA rural communities. The project will
continue to monitor system performance and compiled data will be analysed to characterise system performance, allow PV
deployment system design and facilitate product roll-outs across under-developed rural communities.

Planned Impact

Vast amounts of agricultural produce are wasted in the post-harvest phase in the Sub-Saharan African countries as a result of inadequate food processing and preservation. Postharvest losses in the food chain are estimated to range from about 15% for cereals up to 50% for fresh fruit and vegetables in some developing countries. This can be eliminated if the rural communities that are impacted most had access to power and processing equipment that could eliminate the vast amounts of food waste that continues to beleaguer these under-developed communities. Ultra-cheap and ultra-light weight electricity generation products can assist the processing of food in such communities. In addition such cheap and easy to maintain engineering solutions will also facilitate the training and development of the local people who could undertake system design and maintenance with adequate support and product provision.
Sir Joseph Swan Centre for Energy Research (Swan Centre) has established research and collaboration links with KNUST-Kumasi (Ghana), Jomo Kenyatta University of Agriculture and Technology (JKUAT - Kenya), NJALA University (Sierra Leone), Stellebosch University (South Africa) as well as NGOs such as Practical Action Consulting (PAC) in Kenya
and Environmental Foundation for Africa (EFA) in Sierra Leone. Swan centre is currently developing CFD models to optimise hybrid biomass and solar dryer designs in Sub-Saharan Africa context. The centre will seek to facilitate the deployment of Power Rolls within or alongside the food processing solutions such as the aforementioned solar dryer or in
similar food processing capacity in order to improve the reliability and operational time of the solar dryer and assist rural communities in processing and preserving of their agricultural produce and reduce food waste. Swan Centre will also seek to identify and deploy Power Rolls to undertake water pumping duties that facilitate the delivery of either irrigation or
potable water to these communities.
The generation and availability of off-grid power using ultra-cheap PV rolls will enhance the livelihood, sustainability, independence and capability of rural communities in Africa by enabling them to preserve a much greater proportion of their agricultural produce, eliminate hunger that continues to threaten these communities in dry seasons. Deploying the
aforementioned PV rolls to undertake water pumping duties will also ensure security of water supply to these communities and liberate individuals (mostly women) who are tasked with manual collection, transport and storage (or delivery) of potable (or irrigation) water.

Publications

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Description Over the past 36 months the PowerRoll ltd has managed to produce films that in Q1 of 2019 achieve 7.8% overall power conversion efficiencies (the original aim was to reach 10%, from a starting point of 5% in Q2 of 2017). This was due to PV groove ink injection techniques, that also presented challenges for rapid printing of PV films and scaling up the production.
As per Sep 2020, a 2kWe solar PV film and 10kWh Li-Ion electrical storage rig has been fully operational in JKUAT university campus and has been demonstrated to the delegates from African farming communities as well as scientific colleagues extensively by project partners in Kenya. Early results demonstrate extremely promising solar energy yields using PV films and the project team has examined the impact of small-scale solar generation and storage technologies on the preservations of leafy vegetables, avocados and tomatoes. Future work will examine improved preservation of other agricultural crops as well as diary products.
PV characterisation equipment (solar pyranometer, etc.) shipped to Kenya indicate excellent opportunities for PV roll deployment since site-specific total solar irradiance in February 2020 meets maximum available surface irradiance globally (around 1000 W/m2).
Solar PV film was also trialled in this project in India to examine its viability to replace diesel powered water pumps (by TERI India) and also power ice-cream selling carts (by Unilever) and preliminary results show major carbon mitigation opportunities if PV films were rolled out widely in Indian subcontinent.
The project team is working beyond the lifetime of this fund to further explore ultra-cheap PV film potentials to decarbonise Indian agricultural and Ice-cream cart businesses, as well as its potential to improve African food preservation and post-harvest loss reduction.
Exploitation Route Planning for the development of a new ultra-cheap solar-based renewable generation solution in developing countries.
Building confidence in the engineering, agriculture and business sector regarding the appropriateness of PV rolls as an integral part of energy systems in Sub-Saharan Africa, and the Indian subcontinent.
Sectors Agriculture, Food and Drink,Chemicals,Electronics,Energy,Environment,Manufacturing, including Industrial Biotechology

 
Description The lead partner in this project was PowerRoll that is aiming to manufacture the next generation of ultra-cheap film-based solar PV films that can generate electricity on any surface and anywhere in the world at extremely low cost. This makes the application of this technologies extremely attractive in developing countries such as Sub-Saharan African and the Indian sub-continent. The project team was successful in deploying these PV films in 3 locations both in Africa (JKUAT university) and India (TERI and Unilever research centres). During the project PowerRoll examined several configurations of PV films design and manufacturing processes. Newcastle university undertook complementary design and deployment constraints and specification studies that concerned economic and scalable deployment of ultra-cheap PV-films in Africa. At energy system level Newcastle University also established guidelines on the magnitude and persistence of energy requirements for small scale Sub-Saharan African farmers and strategies required for deploying solar-based power conversion and storage equipment in such communities in Africa. Prof Tony Roskilly held multiple workshops attended by a large number of scientific, business and farming delegates to identify requirements specific to African farming communities and the opportunities that may arise for a UK-manufactured renewable energy system (conversation and storage) to provide electrical and thermal energy that can enable remote farming communities to reduce their post-harvest food losses, increase production efficiency, gain food processing capabilities, achieve better dietary and nutritional intake and ultimately be more independent and prosperous. As per Sep 2020, a 2kWe solar generation and 10kWh Li-Ion electrical storage rig has been fully operational in JKUAT university campus and has been demonstrated to the delegates from African farming communities as well as scientific colleagues extensively by project partners in Kenya. This rig together with PV characterisation equipment (pyranometer and associated devices) will enable JKUAT university to examine improved agricultural processes (production, processing and preservation of agricultural and dairy products) in Africa. Additionally the high calibre PV characterisation equipment (solar pyranometer, etc.) is now deployed in JKUAT (Kenya) and early results indicate excellent opportunities for PV roll deployment since site-specific total solar irradiance in February 2020 meets maximum available surface irradiance globally (approximately 1000 W/m2). The project partners will work beyond the lifetime of this project to further examine the application of solar-based energy solutions to improve African farming practices.
First Year Of Impact 2020
Sector Agriculture, Food and Drink,Communities and Social Services/Policy,Construction,Education,Energy,Environment,Government, Democracy and Justice
Impact Types Societal,Economic

 
Title A solar-based energy conversion and storage solution for Sub-Saharan Africa 
Description This science rig is the outcome of the design, specification and air freight of over 15 separate items of research material (pyranometer, datalogger, 2kWp PV film, 10kWh Li-Ion batteries, auxiliaries, software, etc. that weigh nearly 400kg) to JKUAT University in Kenya (Nairobi) in order to build a complete and self-contained energy generation and storage platform with additional instrumentations to characterise the performance of advanced thin-film-based PV rolls and Li-Ion batteries in Africa. This complete kit is aimed at initially examining how such renewable solutions can mitigate post-harvest food losses in Sub-Saharan Africa (SSA), but in coming years and with future funding will assist in characterising the role of solar-based distributed generation and storage to improve agricultural processes (production, processing and preservation of agricultural and dairy products) in Africa. 
Type Of Material Improvements to research infrastructure 
Year Produced 2021 
Provided To Others? Yes  
Impact This rig arrived in Kenya in Jul 2020 and was first commissioned in late summer 2020. There potentials of this solar based solution was communicated in [1] Africa's innovation incubator seminar 2020 and [2] a field Training of Kenyan farmers to demonstrate usage/operation and maintenance of the improved charcoal cooler powered with this solution in Autumn 2020. A much greater utilisation of this rig will be facilitated in the coming years with on-coming future projects. 
 
Title Solar energy characterisation tools 
Description The project team successfully specified, procured and setting up a complete pyranometer research rig required for our African partners to be able to independently characterise the performance of any solar PVs in Kenya. This includes a calibrated Delta-T sunshine pyranometer (manufactured in Cambridge, UK), levelling baseplate, supporting structure and arm, self-contained data-logger with analogue and digital interface and all connection equipment, software and auxiliaries to allow high resolution solar data collection (both direct and diffused solar irradiance) which will allow performance characterisation of PVs but also assist with JKUAT agricultural studies. 
Type Of Material Improvements to research infrastructure 
Year Produced 2020 
Provided To Others? No  
Impact This pyranometer based tool, together with wind and temperature data from a nearby local weather station (at JKUAT) is able to assist the Kenyan project partners to fully characterise the performance of PV films in African context. This is instrumental in the development of PV technologies in Africa as while Africa is solar-rich, the degradation of PV panels due to (for instance) greater level of dust and air-borne pollutions in Sub-Saharan Africa is little understood. This scientific platform together with the 2kWe PV-film/10kWh Li-Ion storage delivered in this project enables our African partners to be able to completely explore the performance of solar PV on site, generate data on multiple tilt angles across the full annual cycle and make recommendations on optimal deployment details of solar technologies for the farming corporates as well as wider scientific community and other stakeholders in Africa. 
 
Description Collaboration with Big Solar Ltd. 
Organisation Big Solar Ltd
Country United Kingdom 
Sector Private 
PI Contribution Newcastle University has worked closely with Big Solar Ltd and has undertaken research into the state of the art efficiencies in the CIGS-based PV film manufacturing, the robustness and specification of the PV roll kit needed for deployment in rural African sites, and modelling of the system performance onsite.
Collaborator Contribution Refining techniques of the PV film process, device lifetime testing and lab-based trials to achieve greater consistency of output leading to a power conversion efficiency of 7.8% during the first quarter of 2019.
Impact Big solar PV rolls achieving a power conversion efficiency of 7.8% during the first quarter of 2019.
Start Year 2018
 
Description Jomo Kenyatta University of Agriculture and Technology (JKUAT) 
Organisation Jomo Kenyatta University of Agriculture and Technology (JKUAT)
Country Kenya 
Sector Academic/University 
PI Contribution Newcastle University has established strong working relationships with Prof Christopher Kanali (JKUAT University, Kenya) and as such the first Sub-Saharan African deployment site has been identified as the rooftop (and later the grounds of) a food drying and processing facility within the university campus (comprising 16sq.m char-coal evaporative cooling station, 12sq.m office and 20sq.m preparation area). The JKUAT partners have completed a comprehensive audit of the electrical loads within this deployment site while Newcastle University team completed a modelling exercise to optimise the size of the PV film to be deployed. While a peak load of 5.06 kW is established a first PV film size of 2kW was designed and manufactured by RenovaGen, which also included a 10kWh Lithium-Ion battery for security of supply and system resilience.
Collaborator Contribution Detailed audit of the first deployment site's electrical loads, and extensive and time consuming administrative work to enable the KJUAT management signing of a contract that enables Newcastle University to make payments for the PV roll deployment and monitoring work conducted by research partners in KJUAT.
Impact PV roll and battery size established and optimised. Contract signed and in place to enable payment for deployment, monitoring and processing work undertaken by KJUAT
Start Year 2018
 
Description Details of PV-film feasibility in Sub-Saharan Africa at Africa's innovation incubator seminar 2020 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Africa's innovation incubator seminar 2020: This seminar intended to bring together specialists from multiple sectors such as agriculture, renewable energy, economics and policy from the wider African community to talk about improved prosperity for Africa through the application of renewable energy in agriculture. It covered the disappointing statistics of cultivated agricultural land in Africa, the poor yield and post-harvest loss figures and how complete PV-based energy solutions designed, shipped, installed and fully operational in this project can assist small scale cooperatives as well as sustenance farmers in securing greater food preservation and improved welfare.
Year(s) Of Engagement Activity 2020
URL https://www.youtube.com/watch?v=YdXeampY3fA
 
Description Stakeholder Engagement 2018 in Tanzania 
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 Tony Roskilly (the project Co-I) chaired a workshops and coordinated visits to Dar Es Salaam in Tanzania (Golden Tulip Hotel) during 1st to 9th Sep 2018 with regional academics, food processing and marketing companies, farmers and other stakeholder. The purpose of the workshops were to discuss and further assess how low carbon and renewable technologies can readily be deployed to support rural communities with limited power infrastructure to reduce postharvest loss and maintain food quality and safety.
Year(s) Of Engagement Activity 2018
 
Description Stakeholder Engagement in Kenya 2018 
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. Tony Roskilly (the project Co-I) chaired a workshops and coordinated visits to Nairobi in Kenya (Hilton Garden Inn) during 1st to 9th Sep 2018 with regional academics, food processing and marketing companies, farmers and other stakeholder. The purpose of the workshops were to discuss and further assess how low carbon and renewable technologies can readily be deployed to support rural communities with limited power infrastructure to reduce post-harvest loss and maintain food quality and safety.
Year(s) Of Engagement Activity 2018