AE Polysilicon

Location: 
Fairless Hills, PA
Type: 
Corporation
Website: 
http://www.aepolysilicon.com

We hope to strategically align ourselves with industry leaders in an effort to create synergies with intentions of bringing down the cost of solar. By developing advanced production technologies we hope to increase the competitiveness of solar energy while creating a sustainable future.

TECHNOLOGY

Our process is on the cutting edge of innovative polysilicon production technology and utilizes an advanced fluid bed reactor technology in a fully closed loop process. Our highly differentiated production process and product have the potential to advance downstream production throughout the entire supply chain. Most of the shortcomings identified by the open-loop process consistent with Siemens reactors, the most common technology employed by the industry, are eliminated by our closed-loop fluid bed process. Our fully integrated closed loop process is one of the most environmentally friendly designs in the industry and produces Granular BB’s instead of typical chunk polysilicon, a value added product which has the potential to improve the manufacturing efficiency of our customers.

There are four key components to our manufacturing process: TriChloroSilane (TCS) production, polysilicon deposition, utilities, and operations management. Operating and optimizing productions will require intimate understanding and careful balancing of these four key components.

Our closed-looped production process is up to 70% more efficient in terms of energy consumption than that of other processes that use silane. The Siemens process is highly energy consuming, with a major part, up to 90%, being dispersed and lost to the cold walls of the reactor. In the Siemens open-loop reactor, the raw materials to produce polysilicon are the most sensitive when it comes to cost and input/output ratio.

Our TCS FBR reactors are also able to operate continuously compared to conventional Siemens reactors which require batch operations. The continuous deposition design gives us the ability to operate a constant extraction system where the Polysilicon BB’s, at the appropriate predefined size is disseminated through the bottom of the reactor. Additionally, by using a closed-loop process, we are able to increase throughput well above that of traditional polysilicon production processes.

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