The China Photovoltaic Business Affiliation estimates that the entire proportion of 182/210 silicon wafers will attain about 75% in 2022, which is able to grow to be mainstream within the business. Because the proportion of huge silicon wafers will increase, the scale and weight of the modules additionally improve rises. At current, the size of the 78-cell 182 modules has reached practically 2.5 metres, whereas the body weight of which reaches virtually 3kg.
New module sorts put current increased calls for for the efficiency of the frames. Aluminium frames are at present the mainstream resolution on this subject, with benefits similar to light-weight, excessive corrosion resistance, excessive power and simple processing and recyclability.
Nonetheless, though aluminium frames are comparatively secure in efficiency, the hole between totally different aluminium body producers in product high quality and value management is widening, on account of extra strict requirements of module corporations on the body power, processing accuracy, manufacturing value and different necessities.
Solely main aluminium body producers which have robust analysis and improvement (R&D) capabilities and an built-in industrial chain to complete the entire course of from uncooked materials to the ultimate product will stay in a dominant place within the business.
Earlier this month, PV Tech spoke with Wei Qingzhu, vice chairman of photo voltaic aluminium body producer Yonz Know-how’s R&D platform.
Based in 2009 and positioned in Changzhou, China, Yonz Know-how has arrange branches and manufacturing bases throughout the Chinese language provinces of Liaoning, Jiangsu and Anhui, in addition to in Singapore and Vietnam. At current, the corporate’s annual capability of photo voltaic aluminium body merchandise is about 40GW, with 80GW of recent capability beneath building.
Up to now two years, the PV business has skilled a number of value surges, which has introduced the business stress to cut back prices. As a module auxiliary provider, what do you consider this drawback and the way has the corporate been affected?
Wei Qingzhu: Initially, let’s check out the business. Up to now two years, polysilicon, glass, movie and aluminium frames all skilled periodical value fluctuation. Now auxiliary supplies are again to an affordable stage. Why did these costs go up? We will make an evaluation of their prices. The principle value element of an aluminium body, welding strips and silver paste, are relying largely on commodities costs. Silver, copper and aluminium commodity costs are all affected by adjustments in provide and demand relations within the world market.
For instance, the height value of aluminium alloy reached RMB25,000/ton (US$3,580/ton) final 12 months, however in 2022 it has dropped to RMB17,000-19,000/ton with an affordable stage and comparatively secure. Equally, silver, copper and polymer supplies, and many others., additionally went via such a fluctuation course of. However the total development for the costs of those industries went secure. Additionally, the connection between provide and demand is one other consideration issue. The provision of aluminium alloy is sort of enough, so the worth shouldn’t be a factor to fret about.
Additionally, logistics prices have been affected to some extent this 12 months by the pandemic. Particularly within the first half of the 12 months, logistics value was comparatively excessive. Nonetheless, Yonz was actively taking duty of the availability chain, guaranteeing the availability of the frames and making each effort to ship them to our clients’ websites.
Aluminium frames have been categorised as a no-cost-reduction PV element. What do you assume? How does the corporate take care of value reductions? What are your measures or options?
In reality, for greater than ten years since Yonz first entered the PV business, PV body prices decreased from RMB0.3-0.35/W to the present stage of RMB0.13-0.15/W, virtually a 60% decline. Other than the development of module effectivity, the PV body value additionally contributed by greater than 50% via structural design, materials improvement, course of enchancment and different strategies. We’ve got been doing “subtraction” for the merchandise. With a purpose to enhance manufacturing capability, and thus scale back manufacturing prices, we have now carried out automation retrofit and clever upgrading of our manufacturing line, and eventually achieved the aim of value discount. However, we’re additionally making an attempt our greatest to enhance the yield and create worth for purchasers via approach and processing enhancements.
As well as, previously two years, though the buying value of some auxiliary supplies has elevated together with commodity costs, we didn’t switch the price stress to our clients, which was recognised and appreciated by them. We’ve got additionally been engaged on the construction modification of our frames. In 2018, we pioneered the introduction of a 55-degree angled body, which achieved an important industrial value discount. Now 99% of the producers within the business have adopted a 55-degree angled body.
Within the 2022 annual assembly of the China Photovoltaic Business Affiliation, we proposed standardisation of the PV body and cancelling the method of sandblasting each for the good thing about our clients. Why do we want standardisation? The price of non-standardised PV frames is increased, and the supply time is lengthy. The rise in a buyer’s body storage may also have an effect on the capital turnover. As well as, we analysed the affect of the body look on the efficiency from the view of the purchasers, and the outcomes confirmed that the sandblasting course of had no affect on the long-time reliability and the mechanical efficiency, and likewise the accuracy of the body, so we additionally put ahead a sequence of requirements together with the body construction, the looks, the mechanical efficiency and the standard.
Via standardisation of efficiency and construction, cancelling sandblasting, look standardisation and different value discount approaches, the price of every ton of frames might be lowered by greater than RMB300. What does it imply? The associated fee per watt can be lowered by RMB0.3 cent, and the price of 1GW can be lowered by about RMB3 million. Assuming annual module shipments of 300GW, the annual value might be saved by RMB900 million, which is able to make an important contribution to the business. That’s why we’re actively selling this work.
The power consumption of aluminium manufacturing and processing, in addition to secure provide in the long run, have been questioned. How do you assume aluminium frames can meet the market demand for greener manufacturing, decrease carbon emission and decrease power consumption?
Yonz Know-how can be taking the initiative to cut back its carbon footprint to fulfil our company and social duty. Our aluminium body merchandise have been assessed by third-party SGS for carbon footprint. Carbon footprint has to do with two elements. The primary is the product manufacturing exercise stage and the second is the carbon emission elements, respectively. Via calculation, our product’s carbon footprint could be very low throughout processing, about 1.3 tons of carbon footprint whereas producing every ton of aluminium body, far decrease than that of different supplies.
In the meantime, the Yonz Changzhou manufacturing facility has put in a 6.5MW distributed rooftop PV plant on its roof and Yonz Chuzhou put in 12MW distributed rooftop PV plant. Inexperienced electrical energy manufacturing has additionally contributed to carbon discount. However, aluminium alloy might be recycled infinite instances, so the precise carbon footprint could be very low from the attitude of the life cycle evaluation (LCA). We’ve got calculated that the carbon footprint is about an equivalence of 15kg of CO2 per kilowatt of the PV module from the aluminium body half from the view of LCA.
From a long-term perspective, we concentrate on materials recycling. We care about whether or not we are going to depart our grandchildren sources or rubbish within the coming 25 years when the module is out of service. Aluminium alloy is totally renewable and might be recycled for infinite instances within the industrial chain. As well as, all the aluminium alloy business pays numerous consideration to the realisation of the double carbon aim. Many upstream enterprises are migrating to locations with wealthy hydropower and solar energy sources. And Yonz Know-how is setting up a brand new manufacturing base in Wuhu, primarily specializing in recycling aluminium scrap as uncooked materials to supply recycled aluminium body merchandise. We’ve got additionally calculated the carbon footprint of the recycled aluminium body with equal to 7-10kg CO2 per kilowatt of module body, which is the bottom amongst all of the body supplies.
With the event of large-size PV modules, they require stronger frames that may face up to increased masses. How does the corporate see this development and what are your options?
From the view of module improvement, the PV business realised that standardisation is essential for mass manufacturing. 182/210 kind module has grow to be a unified mannequin with the identical dimension for producers. On this foundation, the aluminium body is being extensively used and has been confirmed via the take a look at in actual functions. On the identical time, we have now additionally made some enhancements for large-size modules, together with upgrading the fabric from 6063 to 6005 with a purpose to enhance its power. We’ve got additionally made many technical enhancements similar to ageing and annealing.
Giant-size modules put ahead increased necessities for aluminium frames, however this implies not simply increased power and better hardness, but in addition a greater match between the body and different auxiliary supplies similar to glass.
Up to now two years, modules are extra differentiated with extra diversified varieties and sizes to satisfy totally different market calls for. As a packaging materials provider, how does Yonz reply to altering buyer wants?
We’ve got skilled R&D, manufacturing and design groups to satisfy the differentiated wants of shoppers. On the identical time, we have now wealthy manufacturing expertise in moulds, extrusion processing and different facets, which might meet the calls for of assorted software buildings. Moreover the usual body product, we will additionally meet customised necessities, which could be very aggressive within the subject.
As well as, we additionally seen the diversification of module software eventualities, similar to offshore PV crops, desert PV crops and different harsh and excessive environments. Harsh and excessive environments require higher design and materials of the modules, which might solely be achieved by aluminium frames. We will say that the aluminium body is probably the most appropriate product for PV diversified functions.
There are additionally body merchandise made with totally different supplies out there, similar to rubber clamps, metal frames, composite materials frames, and many others. What do you consider them?
Yonz is completely satisfied to see all of the technological progress within the PV business, however the software of recent supplies requires evaluation and analysis by way of product high quality. For instance, metal is simple to corrode and comparatively heavy, with its density 3 times that of aluminium alloy. Thus, the quantity of metal used within the module body is almost twice as heavy as that of the aluminium alloy body. As well as, the matching between the body and different auxiliary supplies as I discussed simply now, the product dimension accuracy, stability and different performances have to be thought of.
Additionally, the metal body is sort of heavy, so its carbon footprint is important. On the identical time, analysis from the LCA, its recyclability and recycling effectivity aren’t good, leading to an unfavourable carbon footprint.
One other instance is the composite materials body. It has some pure defects similar to anisotropy, unstable coating, poor product accuracy and unsatisfying set up within the software, plus it makes use of glass fibre and polyurethane supplies, that are unable to be recycled. That is precisely what I discussed simply now; it’s going to depart behind rubbish after the entire lifetime of about 25 years.
What’s Yonz’s present market share?
At current, the corporate’s manufacturing capability in Yingkou, Changzhou and Chuzhou bases exceeds 40GW in whole, accounting for about 25% of the market share within the business. By the tip of 2023 and the start of 2024, when the Wuhu base and Vietnam base are put into manufacturing, our whole body capability will attain 120GW, accounting for about 30% of the entire business.
Moreover aluminium frames, what different extensions within the product line does the corporate have and what are the plans for the longer term?
Moreover aluminium frames, we’re additionally creating each merchandise and options for BIPV (building-integrated PV) and its software. We’re additionally performing some analysis and improvement within the subject of photo voltaic monitoring and bracket, aiming to make a extra ideally suited mixture resolution for module set up. That is our subsequent step.
