IPP93
A Week in Japan
During early October, my partner Cynthia and I along with about 50 other PV dealers (including many IPP members) from around United States, spent a week touring Kyocera PV plants in Japan. The tour was hosted by Kyocera. Thank you Kyocera.

The purpose of the trip was two fold. One goal of the trip was to increase dealer knowledge of how PV modules are manufactured. The second purpose was to establish a stronger connection, a “partnership”, between Kyocera Japan and their independent US dealers. The trip was very successful on both counts.

Participants from around the US gathered in Los Angeles for a Friday evening social get together prior to our Saturday morning departure. Following a Saturday morning breakfast and tour orientation, the group bussed the short distance to the airport. The flight was 12 hours non stop. Flying west, racing the sun, we arrived at Japan’s Narita airport (near Tokyo) 3 hours, clock time, after we left Los Angeles. However, because we had crossed the international dateline, it was now Sunday, a day later. The group checked into a nearby hotel and most of us went to bed, having been up for more than 24 hours.

Monday morning we left by bus for Kyocera’s Sakura plant, a short distance from Tokyo. Kyocera has established a solar R&D center here where products and systems are developed and tested. Numerous operating systems are tested including ongrid, offgrid, water pumping and telecommunications. All systems are centrally monitored in the main building providing a long term data base of system performance information. Additionally, a 100 kW PV array on the main building provides a significant portion of the plant’s electricity. Opened in 1983, the Sakura plant hosts many international visitors yearly. Pic037

We met with the plant’s staff who outlined the ongoing activities at the Sakura Research center. Currently new work is taking place on roofing systems, building integrated PV and inverter testing and development. Following our sit down session, we were given a tour of the plant and outlying test systems. Many of the offgrid systems were somewhat dated. Not surprising, since some of them were almost 20 years old. Many of us reminisced about our own offgrid systems done in the past. Though every part of this tour was very interesting, I found I was most intrigued by the on going work with inverters. It was quite evident by the number and variety of inverters on display and being tested that this is an area of interest at Kyocera. It was also interesting that the Kyocera staff was a bit non committal on exactly what they were planning in the way of Kyocera branded inverters for export. My opinion is that we need some heavy hitters to enter the inverter field. Currently even the best inverters are not good enough. Reliability still needs to be improved. Inverters need to be at least as reliable as microwave ovens. In the 21st century this should be doable!

As we left the plant, headed for an afternoon of site seeing in Tokyo, we were treated to a moving farewell as the plant’s staff lined up outside and waved us good bye. This royal treatment would be repeated at the beginning and end of each tour in the coming days. Pic93

On Tuesday we took the famed Bullet train south from Tokyo for about 2 hours to the city of Nagoya. There we got on busses, taking our group to Kyocera’s module fabrication plant at Ise. At this factory individual silicon cells are laid out, interconnected, laminated and framed into solar modules. The Ise plant is highly automated. Essentially stacks of silicon cells are loaded at the beginning of the assembly line and fully framed and tested PV modules come out the other end. These lines operate normally without operator intervention, though an attendant monitors each station. It was awesome to watch these operations done with extreme precision and high speed. Unfortunately, for security reasons, there were no photographs allowed. Leaving Ise late afternoon we bussed to Kyoto, arriving in time for dinner. Pic87

Wednesday morning our group visited the Yohkaichi cell plant, about an hour by bus from our Kyoto hotel. At the Yohkaichi plant raw silicon is transformed into PV cells. Once again for security reasons, no photos were allowed. Like the Ise plant, the processes at the Yohkaichi plant are highly automated, using proprietary equipment developed by Kyocera.

The cell material used in Kyocera modules is called polysilicon. Polycrystalline silicon contains many individual crystals, imparting the distinctive “sparkling” appearance to this material. The first step in the production of silicon cells is the melting of granular silicon feedstock and casting it into large (one cubic foot) blocks. The molten silicon is cooled in a controlled environment, resulting in the required crystalline structure. The solid block of polysilicon is sliced into four “loaves” or rectangular prisms each measuring 6 inches square by 12 inches long. Finally these loaves are sliced, creating thin 6 in by 6 in silicon wafers. The next steps transform the silicon wafer into a solar cell. For the wafer to become a cell, a positive – negative polarity must be established. This is achieved by using high temperature ovens to drive small amounts of dopant (phosphorus or boron in minute but controlled quantities) into the silicon crystal. It is the presence of the small number of dopant atoms that alters the electrical conductivity of silicon, making the silicon electrically either positive or negative. The process of using heat to drive the dopant atoms into the silicon crystal is called diffusion. The first layer diffused, is made positive polarity while the second diffusion step, creating the top layer, becomes negative. Once the positive –negative layers are established (p-n junction), the silicon wafer becomes a silicon solar cell capable of making electricity when light hits the top layer. The p-n junction allows electricity to flow across it in only one direction and functions, in this regard, exactly like a common rectifier or diode used in electronics. When light hits the top layer (negative), free electrons absorb the energy of the light and become energized. The energized electrons can not cross the junction from their side and are forced to flow through an external circuit. The electric current can be used directly or its energy can be stored in a battery. Additional steps using a photographic process, etch the front surface of the cell, placing a very fine grid pattern to collect the electric current. Finally flat foil conductors are applied to the front and backside (tabbing) of the cells and then they are solder coated. The cells are then individually tested and sorted for output. Cells from the Yohkaichi plant are shipped to the Ise plant for assembly into modules.

Leaving the cell plant at Yohkaichi, we returned to Kyoto for lunch and a tour of the Kyocera world headquarters building. Approaching from the south, we were presented with a grand view of the 157 kw PV array that clads the entire south face of the 21 story building. Another 57 kw PV array is mounted on the roof giving the building a total of 214 kw. At the building entrance is a clock tower with a bright digital display showing the output of the array. Located in this building are the administrative offices of Kyocera Corporation. The building also houses a gallery of contemporary Japanese artists and a large number of late Picasso drawings. On the second floor is a technology museum and display of Kyocera products. The company manufactures a wide range of high tech products including specialty ceramics, synthetic gem stones, copiers, cameras, bio medical products and PV modules. Pictures132, 139

After lunch our group met with Kyocera management. They outlined the company’s history and its fundamental philosophy best exemplified by the Kyocera Environmental Charter. It states, “Kyocera takes environmental issues seriously. Our Environmental Charter calls for ever-greater efforts to resolve ecological problems. This spirit has led to diverse initiatives throughout our operations to facilitate sustained, harmonious coexistence with our planet.” Complimenting this overarching philosophical position, Kyocera promotes a no nonsense work culture best exemplified by their first motto for success, “work harder than anyone else”.

My understanding of the purpose of the trip and this meeting is two fold. On the one hand, Kyocera wanted to say “thank you” to the US crew selling their products. Secondly Kyocera wants to strengthen and increase US sales of their PV modules. Strengthening Kyocera’s commitment and relationship with the US sales team is designed to build loyalty and future sales. Another purpose of the meeting was for Kyocera to get direct feedback from installers and those selling PV in the United States. The meeting with Kyocera management resulted in some good exchanges. We dealers wanted to know what new modules and related products were coming while Kyocera was interested in our experiences installing their modules and our customer’s feedback.

We explained to Kyocera’s management why they should be lobbying state governments in support of PV incentive programs in the United States. The Japanese management at Kyocera did not fully understand the reason for this. In Japan the grid is a national enterprise and Kyocera focuses its lobbying activities at the national level. We explained that in the United States our national government is currently held hostage by the petro-cartels and that the only significant efforts for PV are happening at the state level. Kyocera management was encouraged to identify key states and work with lobbying efforts in those states to develop incentives for PV.
After the meeting with management, our group toured the building. On the roof we got to examine in detail the 57 kw PV array and the racks of inverters delivering power to the buildings electrical system. The view of Kyoto was outstanding. We also had time to visit the technology museum and art gallery. Our day was climaxed by a buffet dinner and party that evening hosted by Kyocera. Pic121,143

Thursday, our last day in Kyoto, was spent sightseeing. Because Kyoto was not bombed during World War 2, many ancient temples, shrines and historic buildings still stand. Like all major Japanese cities, Kyoto is densely populated. However, throughout the city are numerous islands of green. These areas usually are the sites of temples and shrines. There are more of them in Kyoto than any other Japanese city. Pic168, 190

PV and Japan
In terms of the number of installed kW of PV, Japan far exceeds the United States. Though this was not a tour of residential installed systems, I found my self constantly looking for houses with PV. Looking from the bus or train window did indeed result in a few sitings. However my naïve expectation that I would see lots of roof top PV was not realized. Upon reflection this makes sense. Though the number of kW installed in Japan is significantly greater than the United States, the percentage of households with PV is still very small.

Friday our last day in Japan was spent checking out of the hotel and traveling to the Kansai airport near Osaka. We departed about 5 pm just at sunset. Flying east, now against the apparent direction of the sun’s travel, we arrived 10 hours later in Los Angeles. Amazingly, it was still Friday, Los Angeles time 1 pm, four hours before we left!

Good News – Bad News
Last issue we reviewed the success of the latest California legislation supporting PV. These successes included a continuation of the one megawatt system cap for net-metered systems, continuation of the buy-down program and the establishment of a renewable portfolio standard for renewable generation. I forgot to mention the availability of a 15% California State income tax credit. By coupling the tax credit with the buy down, Californians can realize a payback time of less than 10 years for residential systems.

Unfortunately, the state of California Energy Commission has put the rebate program on hold until the beginning of 2003 because the program has run out of funding. All current reservations are being honored but no new reservations are being accepted until January, 2003. This problem occurred in spite of terrific efforts by the CEC staff to maintain funding. Originally funded at a level of $54 million for the first five years, the CEC had been able to supply a total of $115 million in funding before running out of money. October 29, 2002 was the cut off date for this years buy down program.

Though the buydown program will continue in 2003 at an increased funding level of $24 million per year, this amount is not going to be enough. The reason being, that during the last two years, the rebate program has disbursed about $40 million per year and there is no expectation that demand will lessen. The CEC is currently holding workshops with members of the PV industry for the purpose of resolving the situation. If the program is not changed and the funding for PV remains at $4.50 per watt, it is projected that the program would run out of money during the first 6 months of each year. This “on and off” situation is unacceptable to all. The CEC staff is currently considering a number of recommendations from the PV industry. Among the suggestions presented are to: reduce the rebate amount gradually in small steps over time, use revised “CEC” inverter and module rating methods that yield more accurate “real world” output figures, (the CEC watt rating is the number used when calculating the rebate amount), reserve 60% of each year’s $24 million for small systems under 10 kW, reduce the rebate for small wind systems to $3.50 per watt (it is acknowledged that $4.50 is more than wind needs) and create a varying rebate schedule based on system size (for example; systems under 2 kW get $4.50 per watt while systems 2- 4 kW get $4.00 per watt etc). Other suggestions made that do not affect the amount of the rebate but will improve system design integrity include: requiring kwh metering on the inverter’s output and requiring a yearly kwh ouput estimate as part of the reservation process. The CEC will be incorporating changes based on these recommendations during November, 2002 and have the new program Guidebook ready by January, 2003.

ACCESS:
Don Loweburg, Independent Power Providers (IPP), PO Box 231, North Fork, CA 93643 559-877-7080 Fax: 559-877-2980 don.loweburg@homepower.com www.i2p.org

Kyocera Solar, Inc, 7812 East Acoma Drive, Scottsdale, AZ 85260, Hiroshi Yagi, 800-223-9580 ext 7734
www.kyocerasolar.com

California Energy Commission (CEC), Emerging Renewables Buydown , 1516 9th Street, MS-2, Sacramento, CA 95814-55112, 800 555 7794, http://www.consumerenergycenter.org/buydown/