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GE To Delay Colorado Thin-film Manufacturing Plant

Steve Leone, Associate Editor, RenewableEnergyWorld.com
July 05, 2012  |  36 Comments

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The thin-film competition keeps getting thinner. A week ago, Colorado-based Abound Solar announced it was closing its Longmont facility and scrapping plans for a much larger operation in Indiana.

Now, energy giant GE said it is putting plans for its Aurora, Colo., plant on hold for 18 months in reaction to the continued drop in crystalline silicon solar panels. When the company announced its plans to jump into American thin-film manufacturing nine months ago, it did so in grand fashion. Company officials unveiled a plan for a 400-megawatt (MW) facility that would churn out cadmium telluride (CdTe) panels, the same thin-film technology deployed by Abound. It was an American manufacturing success story born out of Primestar, which GE purchased in 2011.

GE wasn’t preparing for a soft launch. It was pushing ahead hard and fast with the goal of becoming a U.S.-based solar manufacturing leader. To that end, it laid out a plan to introduce a module at 14 percent efficiency or higher and that the product would hit the commercial market by 2013. Now, company officials say they will delay the new plant so they can work on beefing up the efficiency. That was the same approach announced by Abound, when it said this winter that it would temporarily shut down its Colorado lines to work on efficiency. Four months later the company announced it would file for bankruptcy. 

So now, U.S. manufacturing has lost two of its biggest prizes — one a startup and the other an industry leader. In addition to the 400 MW the GE plant was to produce, it would also have created about 350 new jobs. The 640-MW plant that Abound received a Department of Energy loan guarantee to build in Tipton, Ind., represents another 1,000 jobs.

GE, to be sure, is a stable, diversified company. It also remains a player and investor in many renewable technologies. It’s proven to be a company willing to take a chance on technologies that it feels can win a significant segment of the market. Many will surely see the announcement as a lack of confidence in thin film going forward.

The company exuded confidence nine months ago, just as the industry was bracing for trade action against Chinese crystalline silicon panels that were driving down costs and profit margins for American manufacturers. 

“With so much capacity out there, the only companies that can compete are the ones with the right technology and the right cost structure,” said Matt Guyette, GE’s strategy leader for renewables, during a conference call last October. “There’s a lot of companies out there with the wrong cost structure. We see it with their quarterly reports and some of the bankruptcies in the past few months.

“We’ve been watching the space for over 10 years, and we’ve been investing in technologies, and the reason we have not built this plant before is that the technology was not at a point where we were confident that we could compete. We’re there now. We’re confident and we’re scaling up.” 

While the company is saying that it will forge ahead, the delay illustrates once again how rapidly the solar industry is changing.

Image: Delay sign via Shutterstock

36 Comments

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JD Polk
JD Polk
July 19, 2012
Obviously there exists a white paper on this process, could you have it sent to SolarManJD@DCemail.com.
How far along are they in actual commercial production?
and/or are they any finished products in real time testing in the sun; by this I mean a bank of them not just one panel?
nate rey
nate rey
July 18, 2012
Mr. Polk

To continue.

BSi has been around for decades, and the barrier to commercialization, hasn't been heat, at all, but rather, a passivation problem. The highly stressed 'nano-topography' of a BSi wafer leaves an excessively ionized surface, which traps evolved electrons, and negates the current flow.

Natcore's exclusive, mild, STP bath process for Si-film coating provides simultaneously an anti-reflective coating AND and effective passivation of those 'angry ions'. This was considered sufficiently promising to NREL, who holds the BSi patents, that they granted Natcore an exclusive JV access to worldwide production of those patents.

As to the supposed 'thermal asymptote', well. It may well exist, at some level, under some conditions. But NREL, one of the world's most prestigious energy laboratories, doesn't seem to know where it might be. Apparently you do. Give 'em a call.

Furthermore, we NXT shareholders haven't been blandished with strident claims of increased 'maximum-ideal-condition-efficiency' from our management. Rather, the most prospective benefit is from increased harvest in non-ideal conditions of glancing incident light, and overcast. I read that Germany's solar architecture produced virtually no current during the past winter. Widening the 'event horizon' of photo-electric harvest is a very big deal.

And to argue that any thermal mitigation effect would negate this enhanced harvest, specifically under the cooler conditions at which it would most benifically operate, is obvious nonsense.
JD Polk
JD Polk
July 18, 2012
So this is why no one is going to believe your statements… ABOUT YOUR BREAKTHOUGH BLACK SI OR WHAT EVER YOU WANT TO CALL IT….
Listen to your own statement you have made
YOU ARE SELF DEPRICATING…
aGAIN THE PROOF IS IN THE PUDDING.

I REALLY HOPE AND PRAY THIS IS THE TRULLY SUCCESSFUL BREAK THRU...

I WILL BE THE FIRST IN LINE TO ORDER 10,000 PCS

BUT JUST LIKE ME AND ALL OTHERS IN R&D ONLY TIME AND TRIAL AND ERROR WILL TELL...
nate rey
nate rey
July 18, 2012
Mr. Polk

"This Industry has seen so many of these exact same WONDERFUL CLAIMS MADE, had a lot of investors throw money at the FABULOUS NEW BREAKTHROUGH PRODUCT...again I am sorry but it is nothing but HYPE."


This in response to your analyis of Natcore's Black Si. For one so opinionated, you are distressingly ignorant of BSi's potential, and why Natcore's facilitator is a decades-long-awaited event.


"ONCE READY FOR SALE...
This means no real world use for 5 yrs to see if it truly does what it is supposed to…"

You have no idea how close Natcore is to commercialization of Black Si. They have been fine tuning and elaborating on the film depostion device, with multiple layers of patent protection, and 'black box' anti invasion software, for almost two years now. They will have locked up production agreements on more than one one continent, within two fiscal quarters.

"Now let me tell you were its biggest drawback is that they are not telling you.
The reason it could possibly put more electricity out is because it is absorbing more photons that other cells reflect back…this is not rocket science for my Industry it has been tried before and every time you increase absorption you also increase what?
The temperature as it gets hotter all the gains made during absorption are lost in the heat dissipation…in other words in the real world sitting 8hrs in hot sun there will be no major increase in this panels output…."

I have responded to this tediously naive argument more than once. Yes, of course, more light, more heat. And, yes, I will even entertain the possibility that this 'heat mitigation' effect might prove to be non-linear, such that it could provide an asympotic limit to increased efficiency, under some conditions.

But this is a second order effect. Your argument is akin to saying that adding more helium to a balloon will not increase lift, because the increased pressure will densify the helium.

Continued, following
ANONYMOUS
July 11, 2012
Taking Trina panels as an example, they have a mono-Si panel whose cost/Wp =$2.31 last time I checked. They have a cheaper poly-Si panel whose Cost/Wp = $1.80. The poly-Si panel has a panel efficiency of 12.9%. COB (incl wiring, inv, etc) is proportional (less panel cost) to efficiency. First Solar currently has a panel with efficiency = 12.5%, essentially the same as Trina's poly-Si panel. I don't know the cost of the FS panel because it's not often used for residential projects and the true cost of project panels is deal dependent.
Peter Lynch
Peter Lynch
July 11, 2012
EPC is the contracting firm that installs the farm. The best in the world at this time is BElectric out of Germany - but they dolarge MW scale jobs. YOu can do smaller jobs 100KW + for 3.50 per watt or so..with profit.

Any of the major Chinese panels are OK Trina, Yingli etc Best US manufactured supplier is Suniva - excellent panels...very high efficiency and competitive costs. Maybe the best in terms of overall long term LCOE (levelized cost of energy)of the project.
Ajith Weerasinghe
Ajith Weerasinghe
July 11, 2012
Peter, it is for panels and accessories. What is EPC in this context?
Who is cheaper $/W basis?
Peter Lynch
Peter Lynch
July 11, 2012
Supplier ?? Of what - EPC ? Panels ?? Other ??
Ajith Weerasinghe
Ajith Weerasinghe
July 11, 2012
Thanks Peter. Please feel free to send me any other information. But our projects will be several kW range. What supplier would you recommend?
Peter Lynch
Peter Lynch
July 11, 2012
Mark - First Solar is not the cheapest actually. When you count the whole cost of a solar farm installed i.e. all the racks, wires etc you can built it cheaper with crystalline panels - I am hearing prices as low as $2.15 per watt installed in the U.S. for a larger job (10MW) Solar is here - it is just that not many know yet.....
Ajith Weerasinghe
Ajith Weerasinghe
July 11, 2012
What I don't understand is why First Solar cannot sell their stock eventhough their price per watt is the cheapest? I would be buying their modules next year for few projects. JD is right, battle is not within ARE, it is with polluting technogies.

MarkShin
ANONYMOUS
July 10, 2012
Although it's easy to fault thin-film since thin-film manufacturing is not government subsidized (less than a billion in gov loans for development is not equal to $30 billion in grants for dumping). One must remember that in the GTM projection of future winners the only non-Chinese company is First Solar, a thin-film company. Also, one must not forget that Evergreen failed, SpectraWatt failed, Q-Cells failed, and SunPower is in trouble--all Silicon cell manufacturers. Let's not confuse the current market, brought on by government sponsored dumping, with the underlying technologies.
Peter Lynch
Peter Lynch
July 10, 2012
alodum

I looked at Natcore

It is interesting and the basic concept is logical (to capture all three sections of the light spectrum). But it does seem some time away and there is no mention of cost. If you double the efficiency but in doing that triple the cost - it is a no go. But there is a breakthrough needed and the more people trying to find one the better for us all....
JD Polk
JD Polk
July 10, 2012
Alodum... as the Tuna commercials on TV for 40yrs… Sorry Charlie…
This Industry has seen so many of these exact same WONDERFUL CLAIMS MADE, had a lot of investors throw money at the FABULOUS NEW BREAKTHROUGH PRODUCT...again I am sorry but it is nothing but HYPE.
Again in theory, it looks and sounds great...but let me quote Natcores last sentence on own page... Once ready for sale, Natcore's flexible film solar cell array technology will cause a paradigm shift in the market by exceeding the DOE-established price levels needed to achieve grid parity for the price of solar generated electricity....with emphasis on ONCE READY FOR SALE...
This means no real world use for 5 yrs to see if it truly does what it is supposed to…
Now let me tell you were its biggest drawback is that they are not telling you.
The reason it could possibly put more electricity out is because it is absorbing more photons that other cells reflect back…this is not rocket science for my Industry it has been tried before and every time you increase absorption you also increase what?
The temperature as it gets hotter all the gains made during absorption are lost in the heat dissipation…in other words in the real world sitting 8hrs in hot sun there will be no major increase in this panels output….again sorry for raining on your parade…would love for them to disprove me, as we need any real breakthrough for my industry.
Again the real story will be in longevity sitting in hot sun.
This is why 15yrs ago I decides the best thing for the Renewable Industry is to put all 3 on one platform…Solar, Wind and Tidal-Flow on one Platform…if sun is not shinning
Then wind is usually blowing 20 hrs a day in tidal creeks the tide is moving 10hrs in, 10hrs out. Now you have a real generator almost 24/7…
alfred odum
alfred odum
July 10, 2012
Mr Polk-Mr. Lynch and anyone else who is truly interested in SOLAR..
Natcore Technology has developed "BLACK SOLAR", with exclusive
license from NREL. 99.7 percent absortion rate. In discussion with
5 companies to use their Solar Wafers for commercialisation. NXT on
the Toronto Venture Exchange-NTCXF in the US in the grey market.
NO HYPE-Everyone associated with this Co. has Impeccable Credentials
PLEASE !! Do not take my word for it. Check it out for yourself. They have a website--Natcore technology inc. or, natcoresolar.com--
No expensive vaccum furnace-no toxic chemicals-Production costs are
cut in half. THIS IS THE "NEW" TECHNOLOGY FOR THE SOLAR INDUSTRY.
ANY panel manufacturer can use their Technology...Thats my 30
JD Polk
JD Polk
July 7, 2012
Hill... Just sent you an e-mail from SolarManJD@DCemail.com
anyone wishing to know more about the Emerging Markets for Electric Generation or Low Cost Solar Housing any were World Wide
please e-mail me @ that address
we are presently working with the IREO of the United Nations
backed by IMF, WORLD BANK, EM-EX Bank
Michael Hill
Michael Hill
July 7, 2012
Yes Polk. We are in South Africa, an emerging market and where the cost of grid electricity is increasing exponentially as we struggle to overcome 20 years of generating neglect. My company Khaya Readykit manufactures and constructs pre-fabricated buildings - houses, classrooms,etc and is interested to adopt the best cost effective BIPV technology. See web site www.readykit.co.za. Please contact. Mike Hill
JD Polk
JD Polk
July 6, 2012
Thank you Anonymous I could not have said it better...I see we fill the same way and it is a crying shame...
ANONYMOUS
July 6, 2012
Since several additional thin-film PV enterprises have collapsed since I posted this a week ago, let me repeat: As someone who has worked on silicon materials for PV for over 40 years continuously, I find it very disheartening to see the misguided damage that DOE and NREL policies over the past 30 years have done to the prospects and image of PV made in the USA. Instead of focusing the limited resources that were available on the only practical PV material -- crystalline silicon -- expensive, rare, hazardous, or intrinsically inefficient materials systems have been emphasized for funding and hyped to investors, on the blind faith that thin film PV would have to be cheaper. It hasn't worked out that way, and the US has gone from 1st in PV manufacturing to a distant also ran. The image, in the US, of PV as a viable energy source, has been irreparably damaged. It is audacious to whine about other countries making PV at a lower cost than the US is able to achieve, when with prudent focus and government support the US could have been competitive. How are US subsidies for nuclear, oil, and gas energy sources any different from Chinese support for silicon PV?
JD Polk
JD Polk
July 6, 2012
Yes, Dave you hit the proverbial nail on the head...i will stop shouting with the caps... thus the reason to go to were the average price per KW is 25 to 35 cts per KW and now you do not really need subsidies you are now in the money...the average break even point for large solar farm is around 12.5cts per. and when you do as I do make the hybrid generator bringing 2 or more of the Alternatives together on one platform which I've touted for over 15yrs now...you not only have a generator that generates 24/7 but one that lowers overall cost as to specific overall generation… My newest 4way hybrid on landfill application is the strongest yet on par to be comparable with extractive energies with the new next generation Solar, Mag-Lev Vert Wind, Methane Turbine Burning and Plasma Torch and Recovery System WTE on one platform… a landfill… But again only for Emerging Markets not here in USA.
Peter Lynch
Peter Lynch
July 6, 2012
David I understand your comments. But just a few comments and maybe some useful information. 1. All other energy sources are highly subsidized, especially Nuclear which, depending on how you look at it, is totally subsidized. 2. If you are a competitor to GE - good for you. Their track record in SOLAR is abysmal. Solarex, Evergreen, current CadTel company. They are certainly smart folks, but I am mystified by their decisions. 3. In regard to price of solar - it is going to be coming more of a COMBINATION of RISK and PRICE that wins the day. Nuclear for example is too high a price (with 100% subsides ) plus totally unacceptable risk - from the financial side, Time lag consideration, waste and accident. Whereas solar is fast and has no catastrophic risk associated with it. Utility regulators are waking up to this NOW and it is covered well and in detail at the following link: https://www.ceres.org/resources/reports/practicing-risk-aware-electricity-regulation/view
DAVID ALTMAN
DAVID ALTMAN
July 6, 2012
JD must have a high level of emotion re: THIS TOPIC!. Certainly, the solar industry is a higher order of magnitude in technology than carbon fuels and is still trying to work out the kinks. I have been involved since the mid-80's and have seen good advances in efficiencies but not enough to truly make it stand on it's own without government support. I have no issue with support for the R&D phase, but eventually the business must make business sense. If you can't turn a profit on it, then why produce it??? GE (my competitor) has lots of smart people but they just can't make it profitable just yet. Eventually one of us will have a technological break thru and then this industry can stand on it's own, regardless of the specific technology used to manufacture the energy.
Douglas Prince
Douglas Prince
July 6, 2012
JD LIKES CAPITAL LETTERS!!! AAARRRGGGHHHHHH!!!!!!!
Peter Lynch
Peter Lynch
July 6, 2012
jd - impressive.....at 29K what size PV system is built in ? Sounds like a great project that will help thousands of people....best of luck jd...Peter
JD Polk
JD Polk
July 6, 2012
Low Cost Solar Powered Micro Housing for FEMA disaster relief as well as to build in Emerging Markets. for example 875 sq ft 2 bed 1 bath complete turn key home, cost is 29K, with solar PV built into the roofing structure of these poured composite structures thus building the home with the Generation Built in BIPV. another good thing about these they are erected on slabs using locale labor helping poor economies to help themselves. Clinton Initiative loves my homes. Presently will be building manufacturing facility in Dominican Republic so to be able to truck to Haiti. And will set up export from DR to rest of Islands, Cental ,South America and Mexico?
Peter Lynch
Peter Lynch
July 6, 2012
jd - what is your housing proposal that is mentioned in your profile...?? Peter
JD Polk
JD Polk
July 6, 2012
And Thomas you bring up the raining issue of the day... Lets use something else (Literacy) to take eye off the ball...we can not get anything accomplished in USA because we are so divide on trivial issues and this is why I HAVE CHOSEN TO STEP OUTSIDE THE USA...and produce energy were they need it most and are still 75% diesel fuel burned to generate and the Grid is spotty @ best, or not at all...THIS IS WERE THE REAL NEED IS...AND ALL OF THE FINANCIAL GURU'S AND WIZARDS SAY THE SAME THING? THE ONLY PLACE THIS INDUSTRY IS POISED FOR GROWTH? the Emerging Markets Carib, Central and South America
Tom Leiper
Tom Leiper
July 6, 2012
The marketplace will determine the best resource exploitation and allocation better than the masterminds ever will. As the non-renewable fuels get scarcer or more expensive to exploit, such as to comply with greater public demand for cleanliness, other technologies will fill the void. I really don't understand why those who hate fossil fuels are always warning us that they are not renewable. . . I should think the sooner we ran entirely out of those evil fuels, all the miners and roughnecks were on welfare and the highest possible cost of energy was imposed upon the balance of evil Western society the happier they would be.
Peter Lynch
Peter Lynch
July 6, 2012
Eric - I am curious. Can you elaborate on applying RoHS standards to solar. I know what they are - just would like you to elaborate.
Thomas M
Thomas M
July 6, 2012
Sounds all to familiar with other energy situations. Demoting one technology based upon the cost of another. Remember years ago when solar once again started to emerge as a viable technology then got shot down as soon as oil and gas supplies magicly increased and cost went down? Thin film works just as any other solar product. It has it's uses and applications. The idea is to use all forms of RE in order to reduce and eventually eliminate our fossil fuel dependance. Ignoring one, of only a few solutions, solely on monetary terms, isn't right in my mind. I'ts almost like complaining about someone's spelling even though you understarnd teh works
Lee Angers
Lee Angers
July 6, 2012
Polk, I agree with your last comment, but geez you are a bad speller!
JD Polk
JD Polk
July 6, 2012
Nick, I appreciate your apology...but Son you gat'ta go a long way to insult THE LIKES OF me… I'm glad to have this discussion it is to bad we can't have it on the 6PM news so the world will hear the truth about the carpetbaggers and scallywags that have jumped in this ARE industry (Alternative Renewable Energy)with out knowing anything and have almost destroyed any effort at GETTING TO THE REAL ROOT OF THE PROBLEM… WE AS A THE HUMAN SPECIES ON THIS LITTLE WET ROCK CIRCUMNAVIGATING THAT BIG OLE BALL OF FIRE IN THE SKY MUST CHANGE THE WAY WE GENERATE ELECTRICTY, OR WE ARE HELLBENT ON OUR OWN INAILATION… THE LARGEST POLLUTERS ON EARTH ARE THE EXTRACTION AND THEN THE BURNING… OF FOSSIL FUELS…THE NEXT CLOESEST THING IS WAY DOWN THE LIST…
JD Polk
JD Polk
July 6, 2012
Eric...I'm going to go out on a limb here... I'll bet you like Nuclear...Clean Coal (wow now there is a misnomer)...Nat Gas Burning...ect. All those fabulous Extractive energies that will just go on and last forever and ever... RIGHT? Instead of REAL R&D IN THE RENEWABLE SIDE OF ENERGY GENERATION... The Solar Industry is still in its infancy... only time and real R&D will make it truly the leader that it will become in the future.
Eric Mathis
Eric Mathis
July 6, 2012
Thin Film... Hmmm? Lets remain true to sustainability and apply RoHS standards to the solar industry...
JD Polk
JD Polk
July 6, 2012
Well, Well Nick I am not an English Major nor am I a good speller or typer...the one thing I am good at is looking at paper trails and facts...look back @ the largest Solar Company Bankruptcies of the last 5yrs the overwhelming majority are THIN FILM COMPANIES... MIGHT ASK WHY???? INSTEAD OF TRYING TO GET IN A PISSING MATCH OVER WHOM MIGHT BE THE BEST EDUCATED COMMENTOR... I HAVE BEEN IN THIS INDUSTRY FOR OVER 20YRS I HAVE USED THE OLD TRIAL AND ERROR METHOD TO PROVE WHAT WORKS AND WHAT DON'T... This is why I am now doing all my projects in the Emerging Markets of the World…my new 4way Hybrid on landfill application Is the 24/7 generator that takes all Renewable's and puts them on one platform…Solar. MAG_LEV Wind, Methane Turbine Burning And Waste to Energy Plasma Gasification…. The modern world demands a solution to two of its most perplexing challenges: finding new sources of clean fuels for transportation and electricity, and disposing of the millions of tons of waste produced each day in a safe and environmentally-responsible manner. The trash just keeps on mounting up…more and more as time goes by in every Country in every part of the World… This is a Major Global Problem…that I address…
JD Polk
JD Polk
July 6, 2012
It always amazes' me when a technology that rally doesn't work and has no real ROI slowly withers and dies on the vine ...like a plant with no water... The thin Film Industry was a fluke in 1999 that a bunch of Venture capitalist (IDIOTS LIKE BAIN CAPITOL) would taught to all those unsuspecting investors that really had no clue… just like their brokers...but it was "the big new brake thru" so come on down and invest heavily... This is what has ruined my Industry over the last 10yrs PEOPLE THAT REALLY HAVE NO KNOWLEDE OF WHAT WORKS AND WHAT DOES'NT AND THROWING AWAY BILLIONS OF DOLLARS ON LOST CAUSES THIN FILM DOES NOT WORK, WILL NEVER COMPETE AGAINST POLY AND MONO CRYSTAL CELLS PERIOD IN OUT PUT PER SQ INCH AS WELL AS LONGIVITY IN GENERATION….

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Steve Leone

Steve Leone

Steve Leone has been a journalist for more than 15 years and has worked for news organizations in Rhode Island, Maine, New Hampshire, Virginia and California.
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