Impact of some key plasma reactor performance parameters on the required price of single- and tandem-junction α-Si modules

A previous analysis of PV module manufacturing cost showed that single- and tandem-junction α-Si modules may potentially be manufactured and sold in the $0.90/Wp to /1.60/Wp range if certain key processing parameters primarily associated with the plasma reactor are achieved. This paper compares in more detail tradeoffs in those parameters for both α-Si:H and α-Si:H/α-SiGe:H modules in the context of a 25 MW/yr manufacturing operation, as computed using a previously developed costing model called Interactive Manufacturing Cost Analysis Program (IMCAP). For these technology scenarios, achievement of sub-$1/Wp not only requires module efficiencies of at least 12-15%, but also plasma reactor yields >90%, i-layer depositions approaching 25A/s, and gas utilizations approaching 50%