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PV facilities: opportunities for conversion and re-use of semiconductor fabs

Nate Monosoff, CH2M HILL, Oregon, USA

results of a CH2M HILL study comparing the requirements for a generic 100MW a-Si manufacturing toolsetCrystalline wafer and thin-film photovoltaics manufacturing have experienced dramatic expansion in recent years, but future growth requires increasingly effective strategies to reduce costs and increase the competitiveness of PV power. Reducing PV manufacturing costs has been a prime focus of the industry. In the current climate, cost reduction is especially critical given the industry shakeout that many analysts are forecasting. Now more than ever, it is important to bring manufacturing capacity online quickly and cost effectively. The vast majority of commercial-scale PV manufacturing capacity is new construction (greenfield), meaning it is purpose-built on an unused piece of land; however, there are alternatives. This paper will outline opportunities for re-use of existing obsolete semiconductor fabs, and the steps required to convert from one manufacturing strand to another. This is an approach that offers manufacturers the potential advantages of reduced costs, more rapid ramping of plants to produce finished product, and the superior sustainability achieved through the re-use of existing facilities.

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