Norway-based Norsun is a leading supplier to the solar energy market. Recently, the company embarked on construction of a new facility that would enable it to increase production of its silicon wafers for use in solar cell production. The drivers behind the project included Norsun’s desire to increase market share and move closer to attaining its goal of becoming the leading global supplier of silicon wafers for high efficiency solar cells.
One of the challenges the company faced was reducing the cost of producing single-crystal silicon, the base materials used in the cells. The furnaces typically used in the crystal-growing process are the same as those used in the semiconductor industry. That industry’s stringent parameters for cleanliness and quality control require complex design specifications for crystal-growing furnaces and subsequently higher manufacturing costs.
Solar Industry-specific Design
Among the companies Norsun reached out to for assistance was Kayex®, an SPX company recognized for developing and manufacturing crystal-growing furnaces for both the semiconductor and solar industries.
At the time, Kayex was already applying its expertise in the semiconductor industry to the design of a furnace geared specifically towards the needs of the solar industry. Working with Norsun, Kayex further modified this design to fit the specifications Norsun had determined would best meet their objectives.
Out with the Unnecessary
The resulting Kayex design incorporated a chamber that could accommodate a longer ingot, which would result in the creation of more silicon wafers. Wafers are created by cutting the ingot.
Kayex also helped to reduce costs from the equipment by eliminating the extraneous design details that would have been required had the equipment been developed for the semiconductor industry.
By designing a crystal-growing furnace specifically to meet Norsun’s manufacturing needs, Kayex was able to help the company to cost effectively increase production in its new plant.