At this year's intersolar North America show, M+W's Ankush Halbe, Technology Director Renewable Energy, presented the latest PV capacity drivers as well as successfully proven fab design concepts opportunities complying with the environmental and security requirements.

1. Factory Infrastructure for PV Manufacturing
San Francisco, July 11, 2017
Ankush Halbe
Intersolar – North America

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Contents
• Company Overview
• PV Capacity Drivers
• Fab Design Concepts
• Environmental Considerations
• Safety Considerations
• Fab Statistics
• Fab Energy Management
• Summary

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Advanced Technology Facilities
Global EPC Company
Semiconductor
Leading Player
With global reach
$3.05B
Annual order intake
In 30+
Countries
Renewable Energy
Research Institute Displays
1912
est. in Germany

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Advanced Technology Facilities
Track Record
• >12 Gigawatts of PV Manufacturing
Capacity built
• >45 Million SF of Cleanroom Space
Delivered
• >21,000 Process Tools Installed
• >500 MW installed for C&I clients for
onsite power & utility-scale projects
• Complete solar offering from
wafering through to financing and
O&M services for PV installations

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M+W International PV Projects
Europe AsiaAmericas
Representative Clients
6

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Fab Engineering & Construction
Lifecycle
Site Analysis
Concept
Design
Preconstruction
Planning
Feasibility
Studies
Issued-for-
Construction
Construction
Management
Tool
Installation
Operations
Renovation New Construction

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PV Capacity Drivers
Global PV Demand
Source: GTM Research
Demand for PV modules continues to grow, although at a slower, more sustainable pace (+7% YOY)

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PV Capacity Drivers
Near-term Module Prices and Capacity Trends
• Module prices continue to drop to historic lows,
squeezing margins of PV manufacturers
• With excess module capacity, it is challenging
for manufacturers to spend on additional
CAPEX in 2017-18 Source: GTM Research
PERC technology

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PV Capacity Drivers
PV Factory CAPEX Outlook
• Facilities typically account for ~ 20% of overall CAPEX on a new facility
• CAPEX on equipment and facilities growing at a modest pace for 2017-18
• Low utilization of existing manufacturing capacity
• Limited appetite for improving manufacturing productivity
• Limited commercial introduction of major technology innovations
Source: PV Tech, Solar Media

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PV Cell Manufacturing
Process Technology Impact on Facilities Design
The function, operation and shape of any facility are primarily driven by process &
manufacturing requirements
Equipment & Automation
Production Environment
Critical Process Systems
Site Infrastructure
Building & Facility Systems
ProcessPower
DI-Water
PCW
Make-up Air
Chemicals
Specialty
Gases
Acid Pyrophoric
Solvent Exhaust
Wafer Solar Cell
Compressed
Air
Bulk
Gases
Waste Water
Heat
Exhaust

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PV Cell Manufacturing
Sample Tool Utility Matrix
Utility consumption from process tools determines the type and capacity of facility systems for the
fab (e.g. for exhaust, abatement, water, bulk-gases, power, etc.)
Process
Category AF MF [kW] AF MF [kW] AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF AF MF
Glass clean - substrate
20.00 230.00 0.5 1.0 2,500 2,500
3.0 3.0 12.2 0.50 2.00 15 50 2 10
0.50 2.00 10 30
3.0 3.0 12.2 2.00 500.00 0.50 2.00 15 50
15.80 80.00 20.00 230.00 0.5 1.0 2,500 2,500
3.0 3.0 12.2 0.50 2.00 15 50 2 10
0.50 2.00 10 30
3.0 3.0 12.2 2.00 500.00 0.50 2.00 15 50 2.00 500.00 2 10
Mo Sputter 12.0 12.0 41.8 1.00 3.00 50 250
400.00 400.00
18.5 18.5 107.4 1.00 3.00 20 80
12.0 12.0 41.8 1.00 3.00 50 250
11.0 11.0 63.9 1.00 3.00 20 80 600 600
P1-Laser 6 22 500 500
6 22 500 500
CIG Sputter 2.00 7.00 700.00 700.00 15 50 500 500
2.00 7.00 15 50 500 500
Selenization 12.00 12.00 41.8 28.00 40.00 50 80
12.00 12.00 41.8 28.00 40.00 0.06 0.12 50 80 1,000 1,000
0.06 0.12
CdS 1.00 1.00 24 70 n.a. n.a.
1.00 1.00 24 70 2.00 500.00 n.a. n.a.
1.50 1.50 28 82 2.00 500.00 n.a. n.a.
1.50 1.50 28 82 2.00 500.00 n.a. n.a.
Exhaust
PCW 1
[m3/h]
Liquids
IWD
[l/h]
Drain
CDA
Dew.P < -50°C
[Nm3/h]
SLA-D
[l/h]
Drain-OtherIndustrial Waste Drain
Electrical
CDA
Dew.P < -70°C
[Nm3/h]
NPS 220
[kVA]
General Exhaust
from Laser
N2
4.5
[Nm3/h]
Ar
5.0
[Nm3/h]
DI Water
< 10 µS/cm
[l/h]
Potable Water
[l/h]
General Exhaust
Bulkgases
GEEX
[Nm3/h]
H2S
5.0
[Nm3/h]
PCW 2
T in = 5°C (41°F)
[m3/h]
DEZ
5.0
[Nm3/h]
NPS 480
[kVA]
Laser-EX
[Nm3/h]

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PV Cell Manufacturing
Conceptual Fab Layout

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PV Cell Manufacturing
Conceptual Fab Layout

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PV Cell Fab
Production Environment
• Si cell technologies require minimal clean space; thin-film technologies do not require
any clean space
• ISO 7/8 has regulations on airborne particulate contamination of >0.5um particulate size
• Developing a deep understanding of manufacturing process tolerances for cleanliness,
temperature, and humidity help save facilities cost
Si cell technologies – generic production environments

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PV Cell Fab
Vibration Considerations
Laser & mechanical
patterning tools in
manufacturing area
typically drive any
vibration specs
SEMs, X-ray, and
other e-beam other
optical inspection
tools in FA labs

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PV Manufacturing
Safety Considerations
Source: Fthenakis et al.
• Certain process chemicals and specialty gases used in the PV manufacturing industry
have safety implications
• Gaseous effluents present acute safety hazards; scrubbing is typically required
Hazardous materials used in PV cell manufacturing

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Safety Considerations
Example-Silane Containment Strategies
• ICC (International code council) – CGA G13 determines storage and handling code for Silanes and
mixtures in PV facilities
• Store as minimum volumes as possible
• Store Silane cylinders separately from toxic, corrosive, flammable, oxidizing, and water-reactive
materials
• Locate scrubber for SiH4 outdoors, or in a very ventilated area
• Purge storage cabinets continuously with N2, with highly velocity airflow through several ports
• Consider explosion resistant cabinets with pads, roof, double fences, and fire protection sprinklers
• Install gas monitors, flame detectors with automatic shut-off valves at the cylinder
• Dilute the SiH4/H2 effluent from the process or the scrubber with N2 to lower the SiH4 concentration to
<0.5% before it mixes with air
• Make all exhaust lines of non-combustible material

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PV Cell Fab
Fab Design Statistics
• Fab statistics consider various PV cell technology types
• Facilities infrastructure is generally similar across different PV cell technologies
Cost%
FabArea%

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PV Fab
Generic Pictures
Manufacturing area Facilities Area

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PV Fab
Generic Pictures
Source: PV-Tech / Tesla-SolarCity
Source: Mission Solar Energy

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PV Cell Fab
Fab Construction – Cost Saving Strategies
• Pre-fab buildings
• Modular cleanrooms
• Pre-fab piping racks, equipment skids, etc.
• Process tool installation modules such as high-purity piping
Deploying the use of prefabricated construction modules helps reduce project schedules and
labor costs

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Fab Energy Management
Case Study: Hi-tech Manufacturing Fab
• Energy savings strategy for a fully operational hi-tech manufacturing facility is illustrated
• Learnings are applicable to PV fabs as well
• Efficient design & management of facility systems is a “low” hanging fruit for reducing overall energy
footprint, and can have a potential ROI of <3 years
# System Changes Power Saving Power Saving Natural Gas Saving Energy Cost Saving Payback
MWh/a KW (Peak) MWh/a Years
1 Cleanroom Cleanroom Specification Change 965 150 1159 61,118$ NA
2 Make-up Air Make-up Air Supply Temperature Reduction 589 67 654 44,954$ NA
3 Chilled Water Chilled Water Supply Temperature Increase 687 TBD 40,602$ NA
4 Vacuum Temporary Shut-off 146 33 8,608$ NA
5 Cleanroom Cleanroom Air Velocity Reduction 676 77 39,936$ NA
6 Ultra Pure Water Replace Electric with Hot Water Heating 10186 1170 -11647 421,486$ 1.6
7 Exhaust Heat/Particle Exhaust Recycling 464 53 436 34,217$ 2.1
8 Hot Water Installation of VSD at Pumps 864 215 51,062$ 2.4
9 Chilled Water Installation of VSD at Pumps 1405 TBD 83,036$ 2.9
10 Make-up air Final Filter Replacements 387 44 -430 16,195$ 3.0
Total 16369 1809 -9828 801,214$
Total without risk 15504 1660 -10986 740,096$
Set-point changes
Hardware changes

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PV Manufacturing Facility
Summary: Collaborative Effort to Drive Down Costs
1.0
0.5
0.0
FacilitiesandOperationCost(a.u.)
Technology
Improvement
Fab Safety
Engineering
High
Throughput
Process
Tools
Material
Supply
Chain
Process Equipment
& Technology
Safety
Purchasing
PV Manufacturer Focus M+W’s Value to PV Manufacturer
Fab Energy
Management
Lessons Learnt
Optimized
Building &
Facilities
Industrial Engineering
Energy
Efficiency
Benchmarking

24. www.mwgroup.net
Contact
Ankush Halbe
Ankush.Halbe@mwgroup.net
M+W U.S., Inc.
201 Fuller Road, Suite 401
Albany, NY 12210
518.450.9924
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