成果報告書詳細
管理番号20120000000570
タイトル*平成23年度中間年報 太陽エネルギー技術研究開発 太陽光発電システム次世代高性能技術の開発 太陽電池用シリコンの革新的プロセス研究開発(高純度原料の開発)
公開日2012/10/27
報告書年度2011 - 2011
委託先名太平洋セメント株式会社
プロジェクト番号P07015
部署名新エネルギー部
和文要約和文要約等以下本編抜粋:1. 研究開発の内容及び成果等
高純度結晶シリコン製造の要素技術として、平成23 年度は、平成22 年度に開発したシリカの高純度化プロセスをスケールアップし、工業製品として求められる生産量を実現できる設備を設計することを目的に、各工程のパラメータを定量化し、処理条件の最適化を図った。最適化と併せて、コスト低減についても検討した。また、シリコン製造に必要な高純度カーボンのコスト低減も検討した。
英文要約Title: R&D of solar energy technology/Development of next-generation high-performance technology for photovoltaic power generation system/R&D of innovative silicon processing for solar cells/Development of high-purity materials (FY2010 - FY2012) FY2011 Annual Report
R&D description and outcome: With the objectives of scaling up the silica purification process developed in FY2010 and designing a facility that can handle the production volume required for industrial products, R&D in FY2011 has quantified parameters for various silica purification processes to optimize treatment conditions as component technology for manufacturing high purity crystalline silicon. Cost reduction has been explored along with optimization. Ways of reducing the cost of high purity carbon, essential in silicon production, have also been examined. (1) Cost reduction of high purity silica: a.Alkali dissolution process for silica minerals: The granularity of silica minerals was optimized to shorten the process time and reduce the amount of NaOH. Firstly, the filtering time for silica sol was measured, and was confirmed that increasing granularity of silica minerals could shorten filtering time. It was also found that setting the upper limit of granularity at 1.0 - 2.0mm would keep the rate of silica sol recovery. This has enabled to shorten the silica sol filtering time by approximately 40%. Next, the granularity of silica minerals was set at 1.0 - 2.0mm to examine its effect on NaOH concentration. It was found that lowering NaOH concentration down to 2.0mol/L would not affect the rate of silica sol recovery, and chemical cost (NaOH volume) could reduce approximately 20%. b.Washing process for silica: Efforts were made to optimize the operation conditions for the centrifuge, introduced for washing silica, so as to reduce the amount of ion exchange water required. The study devised a new operation pattern that separates silica washing and dehydration processes, which successfully reduced the amount of ion exchange water by 30%. This led to approximately 50% cost reduction for the washing process. (2) Designing of a plant for mass production of high purity silica: Based on the data obtained through R&D, a master plan for a plant for mass production of high purity silica (400 tons/year) was designed. (3) Cost reduction of high purity carbon (re-commissioned to Tokai Carbon Co., Ltd.): Glassy carbon, carbon black and coke were researched in terms of cost and granularity adjustment. a. Results of carbon materials' purity analysis: The carbon materials, selected for the purpose of cost reduction, were analyzed to determine their purity. It was confirmed that all samples achieved B<1ppm. For materials that necessitate a crushing process, impurity contamination during this process must be addressed. b.Cost estimation of carbon materials: It was found that carbon black and coke have the possibility of meeting the performance and cost sought in this study.
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