Solar Panels in Australia: A Journey of Efficiency and Sustainability

Introduction

Solar panels have undergone a remarkable transformation in Australia, evolving into more efficient and affordable solutions over the past decade. From 2010 to 2024, the efficiency of photovoltaic (PV) modules has surged from 14% to an impressive 23%, a testament to innovation and substantial investments in manufacturing processes. In this article I unravel the intricacies of the solar panel manufacturing process – from inception to assembly, testing, and the environmental impact.

Why Australia doesn’t have junk solar panels?

Australian government basically pays for all the solar panels installed in 98% of all installations. That’s the rebate or STC does . They make sure that the equipment being installed in your house has been audited and complies to standards maintained controls and checked by the Clean Energy Council. They’ve actually done a fantastic job banning and blocking the sale of about 64,000 different solar panel brands. They check their third-party accreditation and even do studies them selves.

Solar Panels Failed ?!

The CEC block manufacturers selling junk or not providing a warranty which is actually happened to me. I had a 8 kW system at Monovale , and Panels kept shorting turning off the inverter ….weeks of tests, the company wouldn’t reply to my emails phone calls and have removed itself from the Australian market. I paid for the new panels and replace them myself because Solarwind Tec guarantees warranty. What’s annoying is I advise the client not to buy the Panels and he went for the cheaper ones ‘won’t do that again’.
When they tried about a year later to re-enter the Australian market, which is means someone wanted to import them Clean Energy Council refuse them to come under the rebate scheme gotcha!! And I warned the importers that this company were cheapskate “fly by nighters}.

Browse the Clean Energy Council’s list

Browse the Clean Energy Council’s list of approved (fire-tested) solar photovoltaic (PV) modules suitable for installation under the Small-scale Renewable Energy Scheme (SRES).

Overview of Solar Panel Manufacturing

The majority of solar PV modules in Australia rely on silicon solar cells, primarily categorized as monocrystalline and polycrystalline. While both types utilize high-purity silicon, their manufacturing processes differ significantly:

Monocrystalline solar cells: These are cut from single crystals grown from molten silicon in a meticulously controlled process.
Polycrystalline solar cells: Manufactured by merging multiple crystals, eliminating the need to grow a single crystal from molten silicon.

Monocrystalline panels boast higher efficiency in converting sunlight into electricity but come with a higher complexity and cost. On the other hand, polycrystalline panels are more straightforward to produce and more budget-friendly, albeit with slightly lower efficiency.

The technical nuances of solar panel manufacturing are intricate, but we’ll guide you through each step of the process, focusing on crystalline silicon solar panels, which command over 90% of the Australian market share. Different panel types, such as thin-film panels, may involve distinct manufacturing processes based on the material used.

Silicon Extraction and Refining

Silicon, constituting 27.7% of the Earth’s crust, is abundant but requires refining to achieve the purity necessary for solar panels. High temperatures are employed to remove oxygen content from mineral silica, resulting in high-purity silicon. The solar industry utilizes 99.9999% pure polysilicon for both polycrystalline and monocrystalline solar cells.

Silicon Wafer Production

Poly cells follow a simpler production process involving casting and cutting polycrystalline silicon blocks into square wafers for PV cells. Monocrystalline cell production is more intricate, relying on the Czochralski method to ensure molten silicon solidifies into a single crystal, cut into solar cells.

Photovoltaic Cell Manufacturing

Manufacturers enhance PV cell efficiency by incorporating controlled amounts of boron and phosphorus, acting as semiconductors. This results in n-type silicon with more free electrons and p-type silicon with electron holes. These are layered into a “PN junction,” the fundamental principle of a solar cell, converting sunlight into electric power.

Solar panels comprise multiple PV cells connected with silver conductors and copper solder. Residential solar panels in Australia typically feature 60 or 72 cells, though some manufacturers produce panels with 120 or 144 half-cells, maintaining similar dimensions.

Encapsulation and Backsheet

PV cells receive an anti-reflective coating to boost sunlight absorption. Solar panels are encapsulated with two layers of ethylene vinyl acetate (EVA) to shield against dust and humidity. Final assembly involves covering the panel with a frontal tempered glass sheet and polymer backsheet.

Solar Panel Assembly and Testing

Solar panels utilize an array of PV sheets encapsulated by polymer layers. The front is covered with translucent tempered glass, while the rear has a weather-resistant plastic backsheet. A rigid aluminum frame provides structural support.

Testing adheres to Standard Test Conditions (STC), including:

Ambient temperature of 25°C (77°F).
Light source providing 1,000 watts of radiation per square meter.
Light spectrum reflecting a common sunlight angle of 48.19° under atmospheric conditions (1.5 air mass spectrum or 1.5AM).

Manufacturers subject panels to tests for hail impact, hurricane winds, and other harsh conditions. Quality modules withstand hailstones with a 1” diameter at 50 mph and winds up to 140 mph. Many residential solar panels in Australia offer a 25-year warranty, lasting over 40 years with regular cleaning.

Is Manufacturing Solar Panels Bad for the Environment?

A study by the National Renewable Energy Laboratory (NREL) indicates a minimal carbon footprint of 50 grams of CO2 equivalent per kilowatt-hour for a solar power system. This includes raw materials extraction, manufacturing, transportation, construction, operation, and decommissioning. In comparison, fossil fuel power plants generate significantly higher emissions.

Conclusion

As solar panel installations surge among Australian homeowners, understanding the intricacies of solar panel manufacturing becomes crucial. The journey from raw materials to the final product underscores the commitment to efficiency, sustainability, and a cleaner energy future.

Keywords: Solar Panels, Solar Technology, PV Modules, Manufacturing Process, Efficiency, Sustainability, Silicon Extraction, Photovoltaic Cells, Encapsulation, Testing, Environmental Impact, Australia, Renewable Energy.