SOLAR MODULE MANUFACTURING UNIT (SOLAR ENERGY OUTPUT)

The project report includes Present Market Position and Expected Future Demand, Market Size, Statistics, Trends, SWOT Analysis and Forecasts. Report provides a comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.

We can prepare PROJECT REPORT as per your INVESTMENT PLAN for BANK LOAN REQUIREMENT and INDUSTRY ANALYSIS. All reports are prepared by highly qualified consultants and verified by a panel of experts.

Have Query? Click Here to Chat
Industry Expert is Online, Chat with him for more detail.

PV Module or Solar PV Module is an assembly of photovoltaic (PV) cells, also known as solar cells. To achieve a required voltage and current, a group of PV modules (also called PV panels) are wired into large array that called PV array. A PV module is the essential component of any PV system that converts sunlight directly into direct current (DC) electricity. PV modules can be wired together in series and/or parallel to deliver voltage and current in a particular system requires.

PV is emerging as a major power resource, steadily becoming more affordable and proving to be more reliable than utilities. Photovoltaic power promises a brighter, cleaner future for our children.

Using the technology we have today we could equal the entire electric production of the United States with photovoltaic power plants using only about 12,000 square miles.

In 1839, Edmund Becquerel discovered the process of using sunlight to produce an electric current in a solid material, but it wasn’t until a century later that scientists eventually learned that the photovoltaic effect caused certain materials to convert light energy into electrical energy.

The photovoltaic effect is the basic principal process by which a PV cell converts sunlight into electricity. When light shines on a PV cell, it may be reflected, absorbed, or pass right through. The absorbed light generates electricity.

In the early 1950s, photovoltaic (PV) cells were developed as a spin-off of transistor technology. Very thin layers of pure silicon are impregnated with tiny amounts of other elements. When exposed to sunlight, small amounts of electricity are produced. Originally this technology was a costly source of power for satellites but it has steadily come down in price making it affordable to power homes and businesses.

CELLS MODULES AND ARRAYS

Photovoltaic cells are connected electrically in series and/or parallel circuits to produce higher voltages, currents and power levels. Photovoltaic modules consist of PV cell circuits sealed in an environmentally protective laminate, and are the fundamental building blocks of PV systems. Photovoltaic panels include one or more PV modules assembled as a pre-wired, field-installable unit. A photovoltaic array is the complete power-generating unit, consisting of any number of PV modules and panels.

Photovoltaic cells, modules, panels and arrays.

The performance of PV modules and arrays are generally rated according to their maximum DC power output (watts) under Standard Test Conditions (STC). Standard Test Conditions are defined by a module (cell) operating temperature of 25o C (77o F), and incident solar irradiance level of 1000 W/m2 and under Air Mass 1.5 spectral distribution. Since these conditions are not always typical of how PV modules and arrays operate in the field, actual performance is usually 85 to 90 percent of the STC rating.

Today’s photovoltaic modules are extremely safe and reliable products, with minimal failure rates and projected service lifetimes of 20 to 30 years. Most major manufacturers offer warranties of 20 or more years for maintaining a high percentage of initial rated power output. When selecting PV modules, look for the product listing (UL), qualification testing and warranty information in the module manufacturer’s specifications.

Cells: Semiconductor device that converts sunlight into direct current (DC) electricity.

Modules: PV modules consist of PV cell circuits sealed in an environmentally protective laminate and are the fundamental building block of PV systems.

Panels: PV panels include one or more PV modules assembled as a pre-wired, field-installable unit.

Array: A PV array is the complete power-generating unit, consisting of any number of PV modules and panels.

Photovoltaic Cell

A single PV cell is a thin semiconductor wafer made of two layers generally made of highly purified silicon (PV cells can be made of many different semiconductors but crystalline silicon is the most widely used). The layers have been doped with boron on one side and phosphorous on the other side, producing surplus of electrons on one side and a deficit of electrons on the other side.

When the wafer is bombarded by sunlight, photons in the sunlight knock off some of excess electrons, this makes a voltage difference between the two sides as the excess electrons try to move to the deficit side.

In silicon this voltage is .5 volt. Metallic contacts are made to both sides of the semiconductor. With an external circuit attached to the contacts, the electrons can get back to where they came from and current flows through the circuit. This PV cell has no storage capacity, it simply acts as an electron pump.

The amount of current is determined by the number of electrons that the solar photons knock off. Bigger cells, more efficient cells, or cells exposed to more intense sunlight will deliver more electrons.

Photovoltaic Modules

A PV module consists of many PV cells wired in parallel to increase current and in series to produce a higher voltage. 36 cell modules are the industry standard for large power production.

The module is encapsulated with tempered glass (or some other transparent material) on the front surface, and with a protective and waterproof material on the back surface. The edges are sealed for weatherproofing, and there is often an aluminum frame holding everything together in a mountable unit. In the back of the module there is a junction box, or wire leads, providing electrical connections.

There are currently four commercial production technologies for PV Modules:

Single Crystalline

This is the oldest and more expensive production technique, but it’s also the most efficient sunlight conversion technology available. Module efficiency averages about 10% to 12%*

Polycrystalline or Multicrystalline

This has a slightly lower conversion efficiency compared to single crystalline but manufacturing costs are also lower. Module efficiency averages about 10% to 11%*

String Ribbon

This is a refinement of polycrystalline production, there is less work in production so costs are even lower. Module efficiency averages 7% to 8%*

Amorphous or Thin Film

Silicon material is vaporized and deposited on glass or stainless steel. The cost is lower than any other method. Module efficiency averages 5% to 7%*

*Check with manufacturer for module’s accurate conversion efficiency.

Photovoltaic Panels

PV panels include one or more PV modules assembled as a pre-wired, field-installable unit. The modular design of PV panels allows systems to grow as needs change. Modules of different manufacture can be intermixed without any problem, as long as all the modules have rated voltage output within 1.0 volt difference.

Photovoltaic Array

A PV Array consists of a number of individual PV modules or panels that have been wired together in a series and/or parallel to deliver the voltage and amperage a particular system requires. An array can be as small as a single pair of modules, or large enough to cover acres.

12 volt module is the industry standard for battery charging. Systems processing up to about 2000 watt-hours should be fine at 12 volts. Systems processing 2000 – 7000 watt-hours will function better at 24 volt. Systems running more than 7000 watt-hours should probably be running at 48 volts.

Category: Tag:

Description

INTRODUCTION
CELLS MODULES AND ARRAYS
PHOTOVOLTAIC CELLS, MODULES, PANELS AND ARRAYS.
PHOTOVOLTAIC CELL
PHOTOVOLTAIC MODULES
SINGLE CRYSTALLINE
POLYCRYSTALLINE OR MULTICRYSTALLINE
STRING RIBBON
AMORPHOUS OR THIN FILM
PHOTOVOLTAIC PANELS
PHOTOVOLTAIC ARRAY
PROJECT LOCATION- KADAPA DISTRICT
MAP
CLIMATE
TRANSPORT
KADAPA AIRPORT TERMINAL
ROADWAYS
RAILWAYS
AIRWAYS
HISTORY OF PHOTOVOLTIC CELLS
TYPES OF PV MODULE
CRYSTALLINE SILICON PV MODULE
(I) SINGLE CRYSTALINE (MONO-CRYSTALLINE)
CONSTRUCTION
TECHNICAL SPECIFICATION
ADVANTAGES OF MONOCRYSTALLINE PV MODULE
LONGEVITY
DISADVANTAGES
APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
(II) POLY-CRYSTALLINE (MULTI CRYSTALLINE)
CONSTRUCTION
ADVANTAGES OF POLYCRYSTALLINE PV MODULE
DISADVANTAGES OF POLYCRYSTALLINE SOLAR PANELS
CONSTRUCTION OF PV MODULE
THE 6 MAIN COMPONENTS OF A SOLAR PANEL
PV CELLS
A MONOCRYSTALLINE SOLAR CELL
GLASS
FRAME
EVA FILM
BACK SHEET
JUNCTION BOX
BYPASS DIODES
NUMBER OF CELLS IN MODULE
PROS & CONS OF PV
COMPLETE PHOTOVOLTAIC-BASED ELECTRICAL SYSTEMS:
CONFIGURED SOLAR ELECTRIC SYSTEMS
PHOTOVOLTAIC MODULE PERFORMANCE
PHOTOVOLTAIC APPLICATIONS
PHOTOVOLTAIC BENEFITS
SOLAR CELL I-V CHARACTERISTIC
SOLAR CELL I-V CHARACTERISTIC AND THE SOLAR CELL I-V CURVE
SOLAR CELL I-V CHARACTERISTIC CURVE
THE ELECTRICAL CHARACTERISTICS OF A PHOTOVOLTAIC ARRAY
SOLAR ARRAY PARAMETERS
EXAMPLE OF I-V CURVE AND RATINGS OF A 12 V SOLAR (PV) PANEL
IV CURVE
IDEAL SOLAR CELL
IDEAL SOLAR CELL (SIMPLIFIED)
EFFECT OF TEMPERATURE
THE AFFECTS OF IRRADIANCE
FIGURE :- PV CELL POWER OUTPUT AS A FUNCTION OF VOLTAGE.
EFFECT OF LIGHT INTENSITY
CONCENTRATORS
EQUATION BELOW;
LOW LIGHT INTENSITY
LINE CAPACITY
SOLAR PV MODULE SPECIFICATION
(A) MECHANICAL SPECIFICATION
(B) ELECTRICAL SPECIFICATION
SOLAR SYSTEM TYPICAL AND MINIMUM SITE REQUIREMENTS
MINIMUM SUNLIGHT REQUIREMENTS FOR SOLAR SYSTEMS
THE BOTTOM LINE IS, EVEN SCATTERED SUNLIGHT CAN PROVIDE SOLAR POWER. THE KEY QUESTION THEN, BECOME:
HOW MUCH SURFACE AREA WILL BE REQUIRED IN ORDER TO GENERATE
THE DESIRED AMOUNT OF POWER?
WILL THAT BE AVAILABLE WITHIN THE PROPOSED SOLAR SYSTEM SITE?
WILL A SYSTEM OF THE REQUIRED SURFACE BE BE FINANCIALLY VIABLE,
TO COVER THE COSTS INITIALLY AND TO RECOUP THAT INVESTMENT
OVER TIME?
PLANNING PERMISSIONS AND INSPECTIONS
THERE ARE TWO FUNDAMENTAL ISSUES TO BE ADDRESSED HERE AT
HIGH LEVEL:
THE FOLLOWING LIST IS REPRESENTATIVE OF THE AREAS WHERE REQUIREMENTS WILL NEED TO BE SATISFIED:
STRUCTURAL AND MECHANICAL STABILITY
FIRE SAFETY
ENVIRONMENT REQUIREMENTS (HYGIENE, HEALTH & THE ENVIRONMENT)
SAFETY IN USE
NOISE LEVELS AND PROTECTION AGAINST NOISE (IF ONLY DURING
INSTALLATION)
ENERGY ECONOMY AND HEAT RETENTION
SUSTAINABLE USE OF NATURAL RESOURCES
SOLAR SYSTEM REQUIRED COMPONENTS
AT THE SIMPLEST LEVEL, A SOLAR SYSTEM REQUIRES:
CONNECTING TO YOUR LOCAL POWER GRID
SOLAR SYSTEM TYPICAL REQUIREMENTS
THEREFORE, FOR THE PURPOSES OF GENERAL GUIDANCE,
A TYPICAL DOMESTIC ROOFTOP SYSTEM CONSISTS OF:
APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
ADVANTAGES OF PV PANNEL
DISADVANTAGES OF PV PANNEL
USES AND APPLICATION OF PV POWER PLANT
APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
EXAMPLES OF SOME APPLICATIONS OF PHOTOVOLTAICS
ARE THE FOLLOWING:
AGRICULTURE
INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES
LIGHTING OF STREETS, GARDENS AND PUBLIC TRANSPORTATION STOPS STREET SIGNALLING.
HEALTH
RESIDENTIAL
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR SOLAR PANEL
FABRICATION PROCESS OF MONOCRYSTALLINE SOLAR PV MODULE
A. SOLAR CELL
B. EVA (ETHYLENE VINYL ACETATE)
ENCAPSULANT’S (EVA) REQUIREMENTS:
C. BACKSHEET
REQUIREMENTS OF REAR SURFACE:
D. GLASS
REQUIREMENTS:-
E. JUNCTION BOX WITH BYPASS DIODES & CONNECTING CABLES JUNCTION
CABLES JUNCTION BOX CONSISTS OF THE FOLLOWING:-
F. CONNECTING RIBBON TWO TYPES OF CONNECTING RIBBON ARE
G. SILICONE SEALANT
SEALANT
H. SHORT AND LONG FRAMES (BACKBONE OF THE MODULE STRUCTURE)
MARKET POSITION
PV MODULES MARKET – INDIA
RISING IMPORTS:
DOMESTIC INDUSTRY WOES
WAY FORWARD
RISEN ENERGY
WAAREE
ZNSHINE
VIKRAM SOLAR
ADANI
TRINA SOLAR
RENESOLA
JINKOSOLAR
LONGI SOLAR
CANADIAN SOLAR
GLOBAL MARKET
TECHNOLOGY INSIGHTS
APPLICATION INSIGHTS
GRID TYPE INSIGHTS
REGIONAL INSIGHTS
KEY COMPANIES & MARKET SHARE INSIGHTS
GROWING NUMBER OF UTILITY SCALE SOLAR PROJECTS
WILL AUGMENT THE MARKET GROWTH
PV PRODUCTION LINE
M-01 AUTOMATIC GLASS LOADING
M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
FUNCTION:
DESCRIPTION:
M-03 AUTOMATIC TEMPLATE LOADING
M-04 INSPECTION TABLE
M-05 TABBER AND STRINGER MTS-3000
HIGHLIGHTS:
MAIN FEATURES:
LIST OF EQUIPMENT INCLUDED:
M-06 LAY-UP SYSTEM
M-07 MIRROR INSPECTION TABLE
M-08 AUTOMATIC BUSSING IC100 (3 HEADS
M-9 INTERCONNECTION CHECKING + LABEL PLACING
M-10 EL INSPECTION
M-11 AUTOMATIC FOIL CUTTING AND LOADING
M-12 BUFFER
M-13 LAMINATOR
M-14 AUTOMATIC EDGE TRIMMING
M15 AUTOMATIC OPTICAL INSPECTION
M-16 AUTOMATIC FRAMING UNIT
AUTO FRAME FEEDER (OPTIONAL):
M-17 JBOX WORKING TABLES
M-18 AUTOMATIC JBOX POTTING MACHINE
M-19 JBOX POTTING DISPENSING MACHINE
M-20 JBOX SILICONE DISPENSING MACHINE
M-21 CURING LINE
M-22 MODULE TESTING STATION
M-23 AUTOMATIC MODULE SORTING
M-24 AUTOMATIC GLASS LOADING
M-25 SECOND GLASS LOADING
M-26 AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
M-27 AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
ACCESSORIES
A-01 CELL TESTER
ASSEMBLY LAYOUT
LINE LAYOUT (PROPOSED)
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF SOLAR PV MODULE
RAW MATERIAL
SUPPLIERS OF SOLAR CELL
SUPPLIERS OF EVA ENCAPSULATE
SUPPLIERS OF TEMPERED GLASS
SUPPLIERS OF ALUMINIUM FRAMER
SUPPLIERS OF JUNCTION BOX
SUPPLIERS OF SILICON GEL
SUPPLIERS OF THERMO PLASTIC BACK SHEET
MACHINERY SUPPLIERS
COMPELETE PRODUCTION PLANT
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
MACHINERY PHOTOGRAPHS
AUTOMATIC GLASS LOADING
AUTOMATIC ENCAPSULANT CUTTING AND LOADING
AUTOMATIC TEMPLATE LOADING
INSPECTION TABLE
TABBER AND STRINGER MTS-3000
MIRROR INSPECTION TABLE
AUTOMATIC BUSSING IC100 (3 HEADS)
INTERCONNECTION CHECKING + LABEL PLACING
AUTOMATIC FOIL CUTTING AND LOADING
BUFFER
LAMINATOR
AUTOMATIC EDGE TRIMMING
AUTOMATIC OPTICAL INSPECTION
AUTOMATIC FRAMING UNIT
JBOX WORKING TABLES
JBOX POTTING DISPENSING MACHINE
JBOX SILICONE DISPENSING MACHINE
CURING LINE
MODULE TESTING STATION
AUTOMATIC MODULE SORTING
AUTOMATIC GLASS LOADING
AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
CELL TESTER
PRODUCT PHOTOGRAPHS

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

200 MW/Day

Land & Building

(800 sq.mt.)

Plant & Machinery

US$ 48000000