Packaging III–V tandem solar cells for practical terrestrial applications achievable to 27% of module efficiency by conventional machine assemble technology

A new concentrator receiver containing a 7 mm×7 mm 3J concentrator solar cell with a 37.4% peak efficiency was developed. The receiver design includes a homogenizer, heat-handling (epoxy lamination) technologies and a low-resistance soldered connection and can be applied to various concentrator optics, including dish systems. The outdoor efficiency with a combination of a plastic Fresnel lens, made by low-cost injection molding, reached 27% on a hot summer day under 35.0 °C ambient temperature without additional cooling. With this newly developed receiver, mechanical engineers will be able to design their own concentrator module suitable for their environment, using their mechanical knowledge and local industrial resources. A 400X and 7056 cm² concentrator module was fabricated with 36 concentrator receivers connected in series and the same number of newly developed dome-shaped, non-imaging Fresnel lenses. The power rating was 200 Wp. The peak outdoor efficiency on a clear sky day was 26.8±1.5%. The integrated efficiency over the course of the day was 25.3±1.4%. This is the highest module efficiency that has been achieved using a practical module size and electrical rating.     

Achievement of 27% efficient and 200 Wp concentrator module and the technological roadmap toward realization of more than 31% efficient modules

A 400× and 7056 cm² concentrator module was fabricated from 36 concentrator receivers, connected in series and with the same number of newly developed dome-shape Fresnel lenses. The averaged outdoor efficiency on a clear sky day was 26.8±1.5% (25C STC). This is the highest module efficiency achieved to date using a module of practical size and electrical rating. The heat was dissipated by the module wall and no heat sinks nor external cooling were used. A glass homogenizer was introduced to give uniform illumination to the square cell, and afforded a reasonable assembly tolerance, without the need for optical alignment.     

Design and fabrication of low concentrating second generation PRIDE concentrator

Prototype first generation Photovoltaic Facades of Reduced Costs Incorporating Devices with Optically Concentrating Elements (PRIDE) technology incorporating 3 and 9 mm wide single crystal silicon solar cells showed excellent power output compared to a similar non-concentrating system when it was characterized both indoors using a flash and continuous solar simulator. However, durability and instability of the dielectric material occurred in long-term characterisation when the concentrator was made by using casting technology. For large scale manufacturing process, durability, and to reduce the weight of the concentrator, second generation PRIDE design incorporated 6 mm wide “Saturn” solar cells at the absorber of dielectric concentrators. Injection moulding was used to manufacture 3 kWp of such PV concentrator module for building façade integration in Europe. Special design techniques and cost implications are implemented in this paper. A randomly selected PV concentrator was characterised at outdoors from twenty-four (≈3 kWp) 2nd-G PRIDE manufactured concentrators. The initial PV concentrators achieved a power ratio of 2.01 when compared to a similar non-concentrating system. The solar to electrical conversion efficiency achieved for the PV panel was 10.2% when characterised outdoors. In large scale manufacturing process, cost reduction of 40% is achievable using this concentrator manufacturing technology.     

Study of automotive radiator cooling system for dense-array concentration photovoltaic system

An automotive radiator is proposed for the heat rejection of the dense-array concentrator photovoltaic (CPV) system. Theoretical modeling on the integration of automotive radiator into the cooling system with a specially designed cooling block has been carried out in details. To verify the feasibility of new proposal, the automotive radiator cooling system has been constructed and tested to effectively lower down the temperature of CPV module in a non-imaging planar concentrator prototype with total reflective area of 4.16 m² at solar concentration ratio of 377 suns. During the on-site measurement, it has been observed that the conversion efficiency of CPV module has successfully improved from 22.39% to 26.85% when the CPV cell temperature is reduced from 59.4 °C to 37.1 °C.     

Super high-efficiency multi-junction and concentrator solar cells

III–V compound multi-junction (MJ) (tandem) solar cells have the potential for achieving high conversion efficiencies of over 50% and are promising for space and terrestrial applications.We have proposed AlInP–InGaP double hetero (DH) structure top cell, wide-band gap InGaP DH structure tunnel junction for sub cell interconnection, and lattice-matched InGaAs middle cell. In 2004, we have successfully fabricated world-record efficiency concentrator InGaP/InGaAs/Ge 3-junction solar cells with an efficiency of 37.4% at 200-suns AM1.5 as a result of widening top cell band gap, current matching of sub cells, precise lattice matching of sub cell materials, proposal of InGaP–Ge heteroface bottom cell, and introduction of DH-structure tunnel junction. In addition, we have realized high-efficiency concentrator InGaP/InGaAs/Ge 3-junction solar cell modules (with area of 7000 cm²) with an out-door efficiency of 27% as a result of developing high-efficiency InGaP/InGaAs/Ge 3-junction cells, low optical loss Fresnel lens and homogenizers, and designing low thermal conductivity modules.Future prospects are also presented. We have proposed concentrator III–V compound MJ solar cells as the 3rd-generation solar cells in addition to 1st-generation crystalline Si solar cells and 2nd-generation thin-film solar cells. We are now challenging to develop low-cost and high output power concentrator MJ solar cell modules with an output power of 400 W/m² for terrestrial applications and high-efficiency, light-weight and low-cost MJ solar cells for space applications.     

Effect of high irradiation on photovoltaic power and energy

Solar photovoltaics (PV) is a promising solution to combat against energy crisis and environmental pollution. However, the high manufacturing cost of solar cells along with the huge area required for well‐sized PV power plants are the two major issues for the sustainable expansion of this technology. Concentrator technology is one of the solutions of the abovementioned problem. As concentrating the solar radiation over a single cell is now a proven technology, so attempt has been made in this article to extend this concept over PV module. High irradiation intensity from 1000 to 3000 W/m² has been investigated to measure the power and energy of PV cell. The numerical simulation has been conducted using finite element technique. At 3000 W/m² irradiation, the electrical power increases by about 190 W compared with 63 W at irradiation level of 1000 W/m². At the same time, at 3000 W/m² irradiation, the thermal energy increases by about 996 W compared with 362 W at 1000 W/m² irradiation. Electrical power and thermal energy are enhanced by about 6.4 and 31.3 W, respectively, for each 100‐W/m² increase of solar radiation. The overall energy is increased by about 179.06% with increasing irradiation level from 1000 to 3000 W/m². It is concluded that the effect of high solar radiation using concentrator can significantly improve the overall output of the PV module.     

Enhanced heat dissipation of V-trough PV modules for better performance

A concentrator photovoltaic (PV) module, in which solar cells are integrated in V-troughs, is designed for better heat dissipation. All channels in the V-trough channels are made using thin single Al metal sheet to achieve better heat dissipation from the cells under concentration. Six PV module strips each containing single row of 6 mono-crystalline Si cells are fabricated and mounted in 6 V-trough channels to get concentrator V-trough PV module of 36 cells with maximum power point under standard test condition (STC) of 44.5 W. The V-trough walls are used for light concentration as well as heat dissipation from the cells which provides 4 times higher heat dissipation area than the case when V-trough walls are not used for cooling. The cell temperature in the V-trough module remains nearly same as that in a flat plate PV module, despite light concentration. The controlled temperature and increased current density in concentrator V-trough cells results in higher V_oc of the module.     

Experimental investigation on gasification characteristic of high lignin biomass (Pongamia shells)

Pongamia residue (shells) is the byproduct from the biodiesel processing industry, which is a lignocellulosic biomass material. It is not suitable as feedstock in downdraft wood gasifier due to low bulk density (146 kg/m³) of shells as compared to wood (more than 350 kg/m³). Pelletization and gasification of pelletized shells was carried out in the present work. The heat transfer analysis in pellets of 17 mm and 11.5 mm was also carried out to evaluate thermal properties of this biomass. Shell pellets of 17 mm and 11.5 mm diameter and length in the range of 10–60 mm were gasified in a 20 kW_e downdraft wood gasifier. The complete gasification of pellets with 17 mm diameter could not be achieved because of less porosity and presence of larger thermal gradient within the pellets. The gasification efficiency was 73% for 17 mm diameter pellets which is lower than that of 11.5 mm diameter pellets which was 95%. The calorific value of producer gas generated from smaller diameter pellets was higher (4.66 MJ/N m³) as compared to larger diameter pellets (3.98 MJ/N m³). Tar formation during gasification of smaller diameter pellets was low as compared to larger diameter pellets.     

A study on the fabrication of polycrystalline Si wafer by direct casting for solar cell substrate

Si-wafers for solar cells were cast in a size of 50 × 46 × 0.5 mm³ by a direct casting method. A graphite mold coated by boron nitride (BN) powder was used in order to prevent the reaction between carbon and the molten silicon. Without any coating, the reaction of the Si melt to the graphite mold was very severe. In the case of BN coating, SiC was formed in the shape of tiny islands on the surface of the Si wafer by the reaction between the Si-melt and the carbon of the graphite mold at high temperature. The grain size was about 1 mm. The efficiency of the Si solar cell was about 0.5% under AM1.5 conditions. It was lower than that of a Si solar cell fabricated with a common single- (sc, 3.0%) and poly-crystalline (pc, 1.0%) Si wafer, which showed much lower efficiency than that of other commercial pc- or sc-Si solar cell (10–15%).     

Hydrogen-rich gas production by steam gasification of char derived from cyanobacterial blooms (CDCB) in a fixed-bed reactor: Influence of particle size and residence time on gas yield and syngas composition

Char derived from cyanobacterial blooms (CDCB), by-product of fast pyrolysis of cyanobacterial blooms from Dianchi Lake (Yunnan Province, China) at a final pyrolysis temperature of 500 °C were used as feedstock material in this study. Steam gasification characteristics of CDCB were investigated in a fixed-bed reactor to evaluate the effect of particle size (below 0.15 mm, 0.15–0.3 mm, 0.3–0.45 mm, 0.45–0.9 mm, 0.9–3 mm) and solid residence time (3, 6, 9, 12, 15 min) on gas yield and composition, and experiments were carried out at bed temperature range of 600–850 °C, steam flow rate of 0.178 g/min. The results showed that solid residence time played an important role on steam gasification process, while particle size presented less effect on gasification process; proper particle size and longer residence time were favorable for dry gas yield and carbon conversion efficiency (CCE). At the same time, higher reaction temperature reduced influence of particle size on gasification process, and smaller particle size required less residence time for reaction completed. Maximum dry gas yield and CCE reached 1.84 Nm³ kg⁻¹ and 98.82%, respectively, achieved at a temperature of 850 °C, flow rate of 0.178 g/min, solid residence time of 15 min and particle size range of 0.45–0.9 mm.     

Repair of Pd-based composite membrane by polishing treatment

In this study, the effect of module configuration on the performance of Pd-based membrane devices was examined using a Pd-Au composite membrane deposited on a porous nickel support. Hydrogen permeation flux, recovery, and CO₂ enrichment were experimentally examined using two different modules. The module configuration that had a narrower space between the surface of the membrane and cover plate provided a large linear flow velocity of the gas mixture, which allowed for a reduction in the concentration polarization. The CO₂ enrichment capacity of the membrane module with a space distance of 0.4 mm was 4 times higher than the module with a space distance of 2.5 mm. In regards to the process design, the membrane with an effective area of 16.6 cm² could enrich 40% of the CO₂ at a flow rate of 2000 ml min⁻¹ up to 87% with a hydrogen recovery ratio of >90% at 673 K and a total feed pressure of 1600 kPa.     

Energy recovery by fast pyrolysis of pre-treated trommel fines derived from a UK-based MSW material recycling facility

In this experimental study, a physically pre-treated trommel fines feedstock, containing 44 wt% non-volatiles (ash and fixed carbon) and 56 wt% volatile matter (dry basis), was subjected to fast pyrolysis to recover energy from its organic load, using a 300 g h⁻¹ bubbling fluidized bed (BFB) fast pyrolysis rig. A physical pre-treatment method (including crushing, grinding and sieving) was used to prepare a 0.5–2 mm sized trommel fines feedstock to make it suitable for fast pyrolysis in the BFB reactor. Experimental results from the fast pyrolysis process showed that the highest yield of organic liquid was obtained at around a temperature of 500 °C. However, both char and gas yields increased dramatically at temperatures above 500 °C, as a result of enhanced cracking of organic vapours, which reduced the yield of liquid products. Overall, energy recovery from the pyrolysis products (liquid and gas products as well as char pot residues) ranged from 63 to 70%, generally increasing with temperature. A large proportion of the high ash content (36 wt%) of the feedstock was found in the char pot (>62%), while smaller proportions were found in the reactor bed and some liquid products. The char pot ash residues composed mostly of non-hazardous earth materials and may be applied in bulk construction materials e.g. cement manufacture. Although, there was no problem with the pyrolysis rig during 1 h of operation, longer periods of operation would require periodic removal of accumulated solid residues and/or char pot modification to ensure continuous rig operation and process safety.     

Can cellulose be a sustainable feedstock for bioethanol production?

Bioethanol is a promising substitute for conventional fossil fuels. The focus of this work was to convert commercial cellulose (Avicel^® PH-101) to ethanol. In the first step, cellulose was selectively converted to glucose. Cellulose hydrolysis was carried out under microwave irradiation using hydrochloric acid as catalyst. Process parameters – acid concentration, irradiation time, and power consumption – were optimized. A yield of 0.67 g glucose/g cellulose was achieved under modest reaction conditions (2.38 M acid concentration, irradiation time – 7 min, 70% of power consumption). The glucose thus produced was then converted to ethanol by fermention with yeast (Saccharomyces cerevisiae). The speed, selective nature of the process and the attractive overall yield indicate that cellulose, a vast carbohydrate source, could indeed be a sustainable feedstock for bioethanol production.     

Biodiesel production from swine manure via housefly larvae (Musca domestica L.)

Although biodiesel is a sustainable and renewable diesel fuel, the current feedstock predominantly from edible oils limits the economic feasibility of biodiesel production and thus the development of a cost-effective non-food feedstock is really essential. In this study, approximately 21.6% of crude grease was extracted from housefly (Musca domestica L.) larvae reared on swine manure, and the extracted grease was evaluated for biodiesel production concerning the variables affecting the yield of acid-catalyzed production of methyl esters and the properties of the housefly larvae-based biodiesel. The optimized process of 8:1 methanol/grease (mol/mol) with 2 vol% H₂SO₄ reacted at 70 °C for 2 h resulted in a 95.7% conversion rate from free fatty acid (FFA) into methyl esters. A 90.3% conversion rate of triglycerides (crude grease) to its esters was obtained from alkaline trans-esterification using sodium hydroxide as catalyst. The major fatty acid components of this larvae grease were palmitic (29.1%), oleic (23.3%), palmitoletic (17.4%) and linoleic (17.2%). The housefly larvae-based biodiesel has reached the ASTM D6751-10 standard in density (881 kg/m³), viscosity (5.64 mm²/s), ester content (96.8%), flash point (145 °C), and cetane number (52). These findings suggest that the grease derived from swine manure-grown housefly larvae can be a feasible non-food feedstock for biodiesel production.     

Multi-junction III–V solar cells: current status and future potential

Our recent R&D activities of III–V compound multi-junction (MJ) solar cells are presented. Conversion efficiency of InGaP/InGaAs/Ge has been improved up to 31–32% (AM1.5) as a result of technologies development such as double hetero-wide band-gap tunnel junction, InGaP–Ge hetero-face structure bottom cell, and precise lattice-matching of InGaAs middle cell to Ge substrate by adding indium into the conventional GaAs layer. For concentrator applications, grid structure has been designed in order to reduce the energy loss due to series resistance, and world-record efficiency InGaP/InGaAs/Ge 3-junction concentrator solar cell with an efficiency of 37.4% (AM1.5G, 200-suns) has been fabricated. In addition, we have also demonstrated high-efficiency and large-area (7000 cm²) concentrator InGaP/InGaAs/Ge 3-junction solar cell modules of an outdoor efficiency of 27% as a result of developing high-efficiency InGaP/InGaAs/Ge 3-junction cells, low optical loss Fresnel lens and homogenizers, and designing high thermal conductivity modules.Future prospects are also presented. We have proposed concentrator III–V compound MJ solar cells as the 3rd generation solar cells in addition to 1st generation crystalline Si solar cells and 2nd generation thin-film solar cells. We are now developing low-cost and high output power concentrator MJ solar cell modules with an output power of 400 W/m² for terrestrial applications.     

Modeling of static concentrator modules incorporating lambertian or v-groove rear reflectors

Ray tracing modeling has been used to calculate the performance of static concentrator modules with a geometric concentration ratio of 2 and incorporating very narrow (1–2 mm), long and bifacial cells. The modules utilize either a v-groove or a lambertian rear reflector. It is shown that the use of very narrow cells allows a performance improvement of 5% or more compared to structures incorporating wider cells, in the case of v-groove reflectors. The averaged yearly performance for both types of reflectors is found to be rather similar, with expected light collection in the range 82–86% of that of a module with 100% cell coverage. Experimental measurements on modules with lambertian reflectors are shown to be in good agreement with the results of modeling.     

Effect of substrate concentration on continuous Photo-fermentative hydrogen production from lactate using Rhodobacter sphaeroides

The information on continuous operation and the use of actual waste as a feedstock are essential for the practical application of photo-fermentative H₂ production. For the first 200 days, continuous H₂ production from lactate was attempted using purple non-sulfur (PNS) bacteria, Rhodobacter sphaeroides KD131, under an illumination of 110 W/m². During the continuous operation, 30% of the fermenter volume was replaced by fresh feedstock once a day, and substrate concentration was gradually increased from 5 mM to 30 mM. H₂ production was negligible at 5 mM, which was ascribed to the fact that the electrons contained in lactate were mostly consumed for cell growth and soluble microbial products (SMPs) production. As lactate concentration increased, H₂ production gradually increased and reached a maximum at 20 mM, showing a substrate conversion efficiency (SCE) of 38%, a H₂ yield of 2.3 mol H₂/mol lactate_added, and a H₂ production rate of 309 mL H₂/L-fermenter/d. Further increases of lactate concentration resulted in a drop of H₂ production (<1.0 mol H₂/mol lactate_added). When the feedstock was changed to actual waste obtained from a 1-day lactate fermentation of food waste, stable H₂ production was maintained, but showed a decreased SCE of 24%. It was speculated that the low performance was due to the fact that actual waste contained not only pure lactate but also other organic compounds that could not be utilized by PNS bacteria. In addition, compared to feeding with pure lactate, the electron consumption to the cell growth was higher in feeding with actual waste, which led to the lower performance.     

Performance improvement of a static concentrator module with an asymmetric v-groove backsheet structure

A light-trapping type concentrator module with a new asymmetric V-groove structure at the rear surface is proposed to improve the performance of static concentrator module. Fundamental optical properties of various asymmetric V-grooves are calculated using a ray-tracing method. Based on these results, yearly integrated irradiance ratios of the concentrator module to a conventional flat-plate module are calculated using meteorological data. By the use of Ag as a reflection material, yearly integrated irradiance ratio of concentrator module with an asymmetric V-groove is 1.34, and the occupation area of Si cells in a module can be reduced to 74% compared with a conventional flat-plate module.     

Biomass availability, energy consumption and biochar production in rural households of Western Kenya

Pyrolytic cook stoves in smallholder farms may require different biomass supply than traditional bioenergy approaches. Therefore, we carried out an on-farm assessment of the energy consumption for food preparation, the biomass availability relevant to conventional and pyrolytic cook stoves, and the potential biochar generation in rural households of western Kenya. Biomass availability for pyrolysis varied widely from 0.7 to 12.4 Mg ha⁻¹ y⁻¹ with an average of 4.3 Mg ha⁻¹ y⁻¹, across all 50 studied farms. Farms with high soil fertility that were recently converted to agriculture from forest had the highest variability (CV = 83%), which was a result of the wide range of farm sizes and feedstock types in the farms. Biomass variability was two times lower for farms with low than high soil fertility (CV = 37%). The reduction in variability is a direct consequence of the soil quality, coupled with farm size and feedstock type. The total wood energy available in the farms (5.3 GJ capita⁻¹ y⁻¹) was not sufficient to meet the current cooking energy needs using conventional combustion stoves, but may be sufficient for improved combustion stoves depending on their energy efficiency. However, the biomass that is usable in pyrolytic cook stoves including crop residues, shrub and tree litter can provide 17.2 GJ capita⁻¹ y⁻¹ of energy for cooking, which is well above the current average cooking energy consumption of 10.5 GJ capita⁻¹ y⁻¹. The introduction of a first-generation pyrolytic cook stove reduced wood energy consumption by 27% while producing an average of 0.46 Mg ha⁻¹ y⁻¹ of biochar.     

Application of an electric field for pretreatment of a feedstock (Laminaria japonica) for dark fermentative hydrogen production

When using cellulosic biomass as feedstock for dark fermentative hydrogen production (DFHP), feedstock preparation is essential step for enhancement of biodegradability. In the present work, electric field was newly applied as a novel pretreatment technique to Laminaria japonica, a marine brown algae, as an alternative method for feedstock preparation. A feasibility test was first conducted (20–100 V for 30 min). The highest H₂ yield (93.6 mL H₂ g⁻¹ dry cell weight (dcw)) was achieved at applied voltage of 60 V, while the performance was decreased from applied voltage of 80–100 V due to increasing formation of hydroxymethylfurfural. Subsequently, electric pretreatment conditions (applied voltage and reaction time) were statistically optimized, and a H₂ yield of 102.7 mL g⁻¹ dcw was recorded with applied voltage 58.5 V and reaction time 30 min. This was 96.1% of the predicted value. These findings clearly revealed that the application of electric field as pretreatment method has enormous potential as an alternative method for feedstock preparation in DFHP.