Comsol Case Studies Simulations for Solar

	Simulations for Solar Comsol

Simulations for Solar

Comsol

Technology Category	Analytics & Modeling - Digital Twin / Simulation Analytics & Modeling - Predictive Analytics Analytics & Modeling - Real Time Analytics
Applicable Industries	Renewable Energy Semiconductors
Applicable Functions	Process Manufacturing Product Research & Development
Use Cases	Predictive Maintenance Process Control & Optimization Digital Twin
Services	Software Design & Engineering Services System Integration
Challenge	The semiconductor industry relies heavily on silicon wafers, which are also crucial for photovoltaic (PV) applications. However, the cost per unit of power generated by solar cells needs to be reduced to make solar energy competitive with fossil fuels. EMIX's challenge was to optimize their continuous cold crucible casting (4C) process to produce high-purity silicon efficiently. This process involves numerous variables, including cooling methods, pull rates, and electromagnetic fields, which need to be optimized to improve production efficiency and reduce costs. Read More
About Customer	EMIX is a company specializing in the production of photovoltaic-quality silicon using an innovative continuous cold crucible casting (4C) process. They hold several patents and an exclusive worldwide operating license for this technology. EMIX has been using multiphysics simulation for eight years to optimize their production parameters and improve the efficiency of their manufacturing process. The company aims to reduce the cost of silicon wafers and improve their purity to make solar energy more competitive with traditional fossil fuels. Read More
Solution	EMIX uses COMSOL Multiphysics software to perform simulations that optimize various parameters of their 4C process. These simulations include multiscale electromagnetic and 3D continuous casting simulations, which help estimate inductance and impedance, optimize crucible design, and improve electrical efficiency. The simulations also allow for the input of parameters such as electromagnetic power, crystallization rate, and cooling zone height. By using these simulations, EMIX has been able to achieve a compromise between high production rates and low stresses in the silicon ingots. The Heat Transfer in Fluids and Laminar Flow interfaces in COMSOL were used to calculate phase changes in the silicon as it solidified in the crucible. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Analytics & Modeling - Predictive Analytics

Analytics & Modeling - Real Time Analytics

Applicable Industries

Renewable Energy

Semiconductors

Applicable Functions

Process Manufacturing

Product Research & Development

Use Cases

Predictive Maintenance

Process Control & Optimization

Digital Twin

Services

Software Design & Engineering Services

System Integration

Challenge

The semiconductor industry relies heavily on silicon wafers, which are also crucial for photovoltaic (PV) applications. However, the cost per unit of power generated by solar cells needs to be reduced to make solar energy competitive with fossil fuels. EMIX's challenge was to optimize their continuous cold crucible casting (4C) process to produce high-purity silicon efficiently. This process involves numerous variables, including cooling methods, pull rates, and electromagnetic fields, which need to be optimized to improve production efficiency and reduce costs.

About Customer

EMIX is a company specializing in the production of photovoltaic-quality silicon using an innovative continuous cold crucible casting (4C) process. They hold several patents and an exclusive worldwide operating license for this technology. EMIX has been using multiphysics simulation for eight years to optimize their production parameters and improve the efficiency of their manufacturing process. The company aims to reduce the cost of silicon wafers and improve their purity to make solar energy more competitive with traditional fossil fuels.

Solution

EMIX uses COMSOL Multiphysics software to perform simulations that optimize various parameters of their 4C process. These simulations include multiscale electromagnetic and 3D continuous casting simulations, which help estimate inductance and impedance, optimize crucible design, and improve electrical efficiency. The simulations also allow for the input of parameters such as electromagnetic power, crystallization rate, and cooling zone height. By using these simulations, EMIX has been able to achieve a compromise between high production rates and low stresses in the silicon ingots. The Heat Transfer in Fluids and Laminar Flow interfaces in COMSOL were used to calculate phase changes in the silicon as it solidified in the crucible.

Impact #1	EMIX has been able to optimize their 4C process using multiphysics simulation, leading to improved crystallization parameters and electrical efficiency.
Impact #2	The simulations have allowed EMIX to reduce the number of tests on the pilot furnace, saving time and resources.
Impact #3	The latest series of simulations have demonstrated energy savings of approximately 15% and pulling-rate increases of about 30%, making the 4C method more productive than other standard silicon crystallization processes.

Impact #1

EMIX has been able to optimize their 4C process using multiphysics simulation, leading to improved crystallization parameters and electrical efficiency.

Impact #2

The simulations have allowed EMIX to reduce the number of tests on the pilot furnace, saving time and resources.

Impact #3

The latest series of simulations have demonstrated energy savings of approximately 15% and pulling-rate increases of about 30%, making the 4C method more productive than other standard silicon crystallization processes.

Benefit #1	Energy savings of approximately 15%
Benefit #2	Pulling-rate increases of about 30%

Benefit #1

Energy savings of approximately 15%

Benefit #2

Pulling-rate increases of about 30%

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Overview

Simulations for Solar

Operational Impact

Quantitative Benefit