Frost&Sullivan Polysilicon 2010

“Assessment of Polysilicon Global Market
and it’s Fabrication Technology Landscape”
Final Report for Rusnano
July 26, 2010

Analysis of Polysilicon Value Chain
2
Silicon value chain I
Nearly 10% of the globally produced metallurgic silicon is consumed for high purity silicon for solar and semiconductor industries.
Ingots
Ingots or
or PV
Solar industry Polysilicon
Polysilicon Wafer
Wafer Solar
Solar cells
cells
Blocks
Blocks System
Mono or
multicrystalline
Silica mg
mg -- Si
Si
Monocrystalline
Semiconductor Electronic
Polysilicon
Polysilicon Ingots
Ingots Wafer
Wafer Chips
Chips
industry System
Purified silicon is utilized in solar and semiconductor industries. The crucial for those two sector is
purity of the silicon and its form. The solar industry uses silicon (mono or multicrystalline) of purity level
99.9999 – 99.999999% of silicon (6-8 “Nines”). While semiconductor industry requires much purer
material, i.e. 9 – 11 “Nines” level. Thus, in the past arising solar industry was using “scraps” of
semiconductor silicon of lower purity (mostly from the caps of the ingot). Now, demand from this
market is much higher and silicon producers orient their activities to address this need.
3
Silicon value chain II
Major production steps for a crystalline silicon include:

• Silica is transformed into metallurgical grade silicon, which is an abundant and cheap
commodity used, for instance, as an alloying element with aluminum.
• Metallurgical grade silicon (MG-Si) is subsequently refined into ultra pure silicon, so-called
polysilicon. This step is both capital and energy intensive. Polysilicon is subsequently re-
melted and re-deposited to form ingots, which are then sawn and polished into wafers. This
first part of the value chain is nearly similar for both of the silicon types, only the purity
requirements are less stringent.
• Further, the wafers are processed according to the end user needs. In case of solar cells,
they are polished and prepared with a number of operations including deposition of various
layers, laser grooving, creation of junctions, to form cells. There are two main types of
crystalline silicon cells: mono-crystalline (more efficient in the conversion of sunlight into
electricity, however with higher manufacturing costs) and multi-crystalline (lower in cost to
manufacture, but less efficient than mono-crystalline cells).
• In case of semiconductor grade, the purification step is much more demanding than in solar
grade silicon. The whole system is remelted and transformed into monocrystalline material.
4
Analysis of Polysilicon Value Chain
- mg Si
5
Metallurgical grade silicon in aluminum alloys
Despite of the high purity polysilicon. Metallurgical silicon is used mostly in aluminum industry.
The largest application of pure silicon (metallurgical grade silicon) is in aluminum - silicon alloys,
often called "light alloys", to produce cast parts, mainly for the automotive industry (this represents
about 50 % of the world consumption of pure silicon). The combination of MG- Si and aluminum
offer a decreased melting temperature, increased fluidity of the melt, and decreased contraction
associated with solidification of alloy. The use of metallurgical grade silicon is to strengthen and
harden the aluminum to make it withstand higher temperatures.
Silicon is usually used at the

conditions close to the eutectic
point, i.e. 11.7 wt% of silicon
(typically 12%) and T =577oC.
Demand for silicon for aluminum

alloys will still be high in future
and this market will impact the
total demand for silicon.
6
List of Global MG-Si Producers
Present Capacity (MT

Manufacturer Country Expansion Plans
per year)
North and Latin America
Plans to retool an existing MG-Si plant

Globe Specialty Metals,
USA 153,000 to produce 4,000 tons of solar-grade
Inc
silicon (via Solsil) per year by 2011
90,000 (MG-Si)
Dow Corning USA 1000 – 4000 (solar NA
grade silicon)
50,000 (MG-Si)
Becancour Silicon (now
Canada 3600 (solar grade NA
Timminco)
silicon)
Rima Industrial S/A Brazil 60,000 NA

Ligas De Aluminio S.A.
Brazil 46,000 NA
(LIASA)
Minas Ligas Brazil 22,000 NA
7
List of Global MG-Si Producers (con’t)
Present Capacity (MT

per year)
Europe
Ferroatlantica Spain 223,000 NA
100,000 (MG-Si) Plant 1 has a capacity of 5000 MT. Capacity

of Plant 2 is not confirmed, but will
Elkem Norway 5000 (solar grade produce at least 5000 MT from 2011
silicon) onwards.
United Company
Russia 70,000 NA
RUSAL
Fesil Norway 55,000 NA
RW Silicium GmbH Germany 35,000
Total production was expected to reach

Kazsilicon (TSC Group) Kazakhstan 5000
10,000 MT by the end of 2010
2000 (solar grade

Solarvalue Germany Plans to reach final capacity at 4500 MT
silicon)
8
List of Global MG-Si Producers (con’t)
Present Capacity
(MT per year)
Asia and Oceania
No firm expansion plans at present,
although the company is in talks to expand
Simcoa Operations Australia 33,000 capacity with industrial partners, as the
new capacity will have to be pre-sold prior
to expansion activities.
9
Globe Specialty Metals Inc, USA
Special features: The Company supplies 12% of Silicon materials globally; and have 25% of the global market (apart from China). It
is the largest producer of silicon metal in North America.
Location of Headquarters: New York
Production capacity: It has an installed capacity of 186,000 MT, but produced 156,400 tons in 2009
Expansion plans: Plans to retool an existing metallurgical-grade silicon plant in Niagara Falls to produce solar-grade silicon. The
facility is expected to be in full production by 2011, turning out at least 4,000 tons of solar-grade silicon per year, which will
be finally upgraded to 30,000 tons.
Ownership structure:
• Globe's principal operating subsidiaries are:
• Globe Metallurgical Inc.
• Solsil Inc.
• GlobeMetais Industria e Comercio S.A., Brazil (formerly CCM)
• GlobeMetales S.A., Argentina (formerly Stein Ferroaleaciones) – does not produce MG-Si
• Norchem Concrete Products Inc. – does not produce MG-Si
• On February 29, 2008, the Company completed the acquisition of 81% of Solsil, a company engaged in the
production of high purity metallurgical silicon for use in silicon-based solar cells. Solsil supplies its silicon to
several leading global manufacturers of photovoltaic cells, ingots and wafers
10
Globe Specialty Metals Inc, USA (con’t)
Silicon sources:
• Quartzite mine in Billingsley, Alabama – Owned by Globe Metallurgical Inc’s subsidiary,
Alabama Sand & Gravel Inc.
• Quartzite mine in Pará, Brazil – Globe Metais S.A.
Plants:
• Beverly, Ohio – 32,000 MT MG-Si plant run by Globe Metallurgical Inc. Solsil Inc also has it’s
main plant in Beverly, Ohio, where solar grade silicon metal is produced
• Alloy, West Virginia – 65,000 MT plant run by Globe Metallurgical Inc’s subsidiary, West
Virginia Alloys
• Selma, Alabama – 30,000 MT plant run by Globe Metallurgical Inc.
• Niagara Falls, New York – owned by Globe Metallurgical Inc., but currently idle
• Tucuruí , Breu Branco, Pará, Brazil – 42,000 MT plant run by Globe Metais S.A.
Significant contracts:
• Solsil has a supply agreement that ends in December 2026 for S-1 metallurgical grade for
$1,512,000
• A contract with Dow Corning which begins in 2006, where Dow Corning will purchase 30 000
metric tons of silicon metal per year by the end of 2010
11
Globe Specialty Metals Subsidiary - Globe Metais Indústria e
Comércio S.A., Brazil
Special features: Quartz mines have reserves well in excess of 40 years, at
current production capacity. The company’s energy comes from the
nearby Tucuruí hydroelectric plant -- the fifth largest in the world.
Plant Location: Rodovia PA 263 KM 3,5, Breu Branco – PA – Brazil
Sales Office: Rua Dr. Renato Paes de Barros, 714 - conjunto 21 – Itaim, São
Paulo – SP – Brazil
Production capacity: 42,000 – 44,000 MT per year
Silicon source: Quartzite mine in Pará, Brazil
12
Dow Corning, USA
Special features: Introduced in Sept 2006 the PV industry's first commercially

available solar-grade silicon feedstock derived from metallurgical silicon,
which can be blended with polysilicon in PV applications
Location: Midland, Michigan, USA
Production capacity:
• Metallurgical silicon: 40,000 MT plant in Mt. Meigs. Alabama and a 50,000
MT plant in Campinas, Brazil, operated by Companhia Brasileira
Carbureto de Calcio (CBCC), a subsidiary of Dow Corning. The MG-Si is
assumed to be for Dow Corning’s own consumption.
Expansion plans: Solar grade silicon: Under development in the plant at Santos
Dumont, Brazil
13
Rima Industrial S/A, Barazil
Special features: Leading Brazilian producer of silicon-based alloy
Location: Belo Horizonte, Brazil
Silicon sources: Owns vast reserves of high purity quartz amounting to more than 5
million tons, mine is located in Olhos D’Agua, Brazil
Production Capacity: 60,000 metric tons
Plants: Capitao Eneas, Bocaiuva & Varzea de Palma
14
Ligas De Aluminio S. A. (LIASA), Brazil
Sales office: Avenida Contorno, 1977 – Floresta, 30.110-009 – Belo Horizonte – Brazil
Production capacity: 46,000 MT per year
Plant: Av. Dr. José Patrus de Sousa, 1000, 39.270-000 – Pirapora – Brazil
• Product range:
• % Si = 98.5 (min), % Fe = 0.10 - 0.40, % Ca = 0.01 - 0.25, % Al = 0.05 - 0.25
End user market:
• Aluminum industry
• Silicone (chemicals)
15
Minas Ligas, Brazil
Silicon sources: Mine in Pirapora, Minas Gerais, Brazil

Plants: Pirapora, Minas Gerais, Brazil
End-user market: Produces metallurgical grade, chemical grade and electronics grade silicon,
although other grades can be provided upon customers’ request.
• Aluminum industry
• Chemical industry – silicone, resins, lubricants
• PV and semiconductor industries
Chemical Specifications
Electronic
Elements Standard grade Chemical grade High purity
grade
% Si (min.) 98.50 98.50 98.50 99.0
% Fe (max.) 0.50 0.40 0.50 0.20
% Al (max.) 0.50 0.25 0.30 0.02
% Ca (max.) 0.40 0.03 0.03 0.03
16
Ferroatlantica Group, Spain
Special features: Appears to be the largest producer of metallurgical silicon in the world
Production capacity: 223,000 tons

Expansion plans: NA
Ownership structure: The FerroAtlantica group includes FerroAtlantica and Ferropem. Ferropem was
originally known as Pechiney Electrométallurgie (PEM) of France, where PEM was acquired by the
Ferroatlantica group in 2006..
Silicon sources: The group owns quartz mines in Spain, Latin America and South Africa.
• Quartz mines in Sonia, Conchitina, Esmeralda, Trasmonte, Merlán y Cristina in Galicia, Spain
are run by Industrial Quartzes, a subsidiary of Ferroatlantica
• The quartz mine, Serrabal in Galicia, Spain, is run by RAMSA, a subsidiary of Ferroatlantica
• The mines in Candelaria and El Manteco y El Merey in Bolivar, Venezuela is run by CuarzoVen,
a subsidiary of Ferroatlantica
• The quartz mine in Polokwane, South Africa, is owned by Silicon Smelters, a subsidiary of
Ferropem
17
Ferroatlantica Group, Spain (con’t)
Plants belonging to Ferroatlantica:

• Sabón, Spain – 40,000 tons
Plants belonging to Ferropem:

• Anglefort, France – 36,000 tons
• Château Feuillet, France – 13,000 tons
• Laudun, France – 14,000 tons
• Les Clavaux, France – 35,000 tons
• Montricher, France – 30,000 tons
• Polokwane, South Africa – 55,000 tons. The South African plant is run by Ferropem’s subsidiary,
Silicon Smelters.
Product profile: Produces mostly two types of silicon, chemical grade and metallurgical grade, for the
following sectors:
• Silicone
• Aluminum alloy
• PV and semiconductor market
18
Elkem Solar A/S, Norway
Production capacity:
• Metallurgical silicon: Elkem produced approximately 96,000 MT of MG-Si
from their plants in Bremanger (27,000 tons), Salten (27,000 tons) and
Thamshavn (42,000 tons.
• Solar grade silicon: The company is investing NOK 2.7 billion in building a new
factory at the Elkem Fiskaa plant in Kristiansand, Norway. Now, the plant has
capacity of 6000 MT per year.
Special features: The company is dedicated to converting metallurgical grade silicon

to solar grade silicon, and has developed a multi-step Elkem silicon refining
process that uses the fluidized bed reactor (FBR) method.
19
United Company RUSAL, Russia
Special features: World’s largest producer of aluminum and alumina

Production capacity: estimated as 70,000 metric tons
End user sector: Most of the produced silicon is meant for the parent company’s
aluminum production
Ownership structure: Rusal was formed through the merger of RUSAL, SUAL, and the
alumina assets of Glencore
Plants:
• Irkutsk, Russia
• Ural area, Russia
20
Fesil, Norway (sold to Wacker)
Special features: 90 % of FESIL's products is meant for the EU market
Location: Holla Metal Kyrksæterøra, Norway
Production Capacity: 48,000 tons
Plants: Holla Metall plant, Kyrksæterøra, Norway
Before selling to Wacker, the product profile was : 65 - 70 % of the production goes to the
chemical industry. Others go to:
• Aluminum alloy
• PV and semiconductor industries.
• Silicone oils, silicone rubber, lubricants, sealers, cosmetics and textiles
21
RW Silicium GmbH, Germany
Special features: Germany’s only producer of silicon metal

Location: Pocking, Germany
Plants: Pocking, lower Bavaria
Production Capacity: 35,000 metric tons
Product types:
% Si % Fe % Al % Ca ppm P
min. max. max. max.
Si-Metall 553 98,50 0,50 0,50 0,30
Si-Metall 441 99,00 0,40 0,40 0,10
Si-Metall 3303 99,00 0,30 0,30 0,03
Si-Metall 2202 99,50 0,20 0,20 0,02
Markets: aluminium alloys, chemical, PV and semiconductor industries
22
Kazsilicon, Kazakhstan
Special features: The company has plans to enter the solar market
Location: Almaty district, Kazakhstan
Production capacity: 5000 metric tons
Expansion plans: The infrastructure of the plant has been prepared for a total capacity
of 10,000 MT/yr (It was expected to reach by the end of 2010)
Silicon sources: Owns the Sarykulsk field with explored silicon reserves of 1.7 million
tons
Plant: Ushtobe, Kazakhstan
23
Simcoa Operations, Australia
Silicon sources: Simcoa owns a quartzite mine in Moora, Western Australia. The quarzite deposit
contains more than 2 million tons of proven reserves.
Plants: Kemerton, Western Australia
Expansion plans: Simcoa Operations' $100 million Furnace Expansion was officially launched on
Tuesday 6th April 2010 with a sod-turning / tree planting ceremony to mark commencement
of the project. The new furnace will differ in design from the existing furnaces in that it will be
designed to facilitate energy recovery from furnace waste heat in future.
End-user market: 10% of the company’s production is for the Australian market, and the
remaining 90% is exported overseas to customers in Japan, United Arab Emirates, USA and
other countries. 70% of production is for long-term contractual customers, while 30% is sold
using spot pricing.
• Aluminum (60% of production)
• Chemical industry (40% of production)
24
Analysis of metallurgical silicon market -
Entry barriers; Conclusions
25
Drivers and Challenges for MG-Si Growth
Increased demand
from aluminum, steel
and chemical
manufacturers Development of Development of new
Drivers
Growth of PV solution utilizing processes for material

PV market less pure silicon
purification
Increase in
Political polysilicon Competing
regulations
Challenges
production capacity materials
regarding anti- in next few years for PV and
dumping taxes electronics
industry ...
Note: Size of the sphere identifies the impact on the market
26
Entry barriers for metallurgical silicon producers
11 High
Highcapital
capitalexpenditure
expenditure**
22 High
Highenergy
energyrequirements
requirements
33 Prefered
Preferedproduction
productionclose
closetotothe
thequartz
quartzmining
mininglocations
locations
44 Prices’
Prices’fluctuations
fluctuations
55 Small
SmallROI
ROI
*(~ 150 mln$ for 6000 MT per year facility): Source: Frost & Sullivan
27
Conclusion
The high growth of the PV Industry has created a shortage of solar grade silicon.
Processing metallurgical silicon toward the solar grade silicon is expected to reduce
the shortage of this commodity.
The price of silicon metal has increased due to increasing demand.
Metallurgical silicon upgraded using metallurgical process is viewed as

complementary to Polysilicon and not as a substitute or a threat. Moreover, the
metallurgical silicon upgraded has low potential to challenge polysilicon in the PV
area.
Prices of MG-Si are expected to increase. However, the price level is still much less
than in 2008 maximum. In effect, 2nd (such as amorphous thin film silicon, etc..),3rd
and in perspective 4th generation solar cells have lower market potential to
successfully compete with traditional devices.
28
Analysis of silicon value chain -
Solar and semiconductor grade silicon
markets
29
Regional contribution to the global silicon market
Europe is one of the biggest producer of silicon.
However, Asia is the main producer of silicon wafers
38.0
[%]
27.6
16.4 68.5
14.7 [%]
[%] 10.4 [%]
[%] 9.9 [%]
[%] 73.1
33.3
[%]
[%]
Wafers' market
Wafers'
production
Silicon
production Source: Sage Concepts, Frost & Sullivan
30
Polysilicon main players production capacities
Polysilicon capacity
Others
LDK
OCI 2005
2006
GCL-Poly
2007
Mitsubishi 2008
2009
Tokuyama
2010E
6N Silicon 2011F
2012F
MEMC
2013F
Hemlock 2014F
REC
Wacker
0 50 100 150 200 250 300 350
Capacity [k Tons]
Polysilicon market is perceived as profitable. Its main players invest continuously in new
facilities or upgrade existing ones. The increasing demand for silicon from various markets
stimulates the construction of new facilities. This trend is global and in case of well
established big players includes aggressive plans for production expansion.
31
Analysis of polysilicon value chain -
Entry barriers.
32
Entry barriers for high purity silicon producers
11 Required
Requiredtechnology
technologyexpertise
expertiseand
andknow
knowhow
how
22 Limited
Limitedaccess
accesstotoefficient
efficientand
andreliable
reliabletechnologies
technologies
33 High
Highcapital
capitalexpenditures
expenditures
44 Increasing
Increasingrequirements
requirementsofofsilicon’s
silicon’spurity
puritylevel
level
55 Market
Marketbrand
brandand
andcustomers’
customers’reception
reception
66 Standards
Standardsand
andregulation
regulationdeciding
decidingabout
abouttechnology
technologytype
typeand
andsize.*
size.*
77 Antidumping
Antidumpingregulations
regulations
*Some countries like EU or China banned or plan to ban some production techniques
33
Standards and applications for semiconductor
and solar grades.
34
Contamination and solar/semiconductor purity standards
Among various silicon material and technology standards the most popular are SEMI norms.
Contamination
Contaminationlevel The
level TheSEMI
SEMIand
andJEITA
JEITAbodies
bodiesare
arecontinuously
continuouslyanalyzing
analyzingand
andproviding
providingguidance
guidance
for silicon standards devoted to semiconductor and solar industries
•• Experimental for silicon standards devoted to semiconductor and solar industries
Experimentalstudies
studiesproved
provedthatthat
some metal impurities affect the
some metal impurities affect the
devices’
devices’performance.
performance.InInthis
thisregard,
regard,
the iron, chromium, nickel are
the iron, chromium, nickel are
considered as active elements at the
considered as active elements at the
concentration level 50, 40 and 40 • Semi M6-0707 • Specification for silicon wafers for PV
concentration level 50, 40 and 40
ppm solar cells
ppmwt,wt,respectively.
respectively.
• Semi M16-1103 • Specification for P-Si for electronic grade

purposes
• Semi M24-0307 • Specification for polished mono-c-Si

Silicon
SiliconStandards
Standards premium wafers
•• InInthis
thisregard
regardvarious
varioussilicon
silicon
associations • Semi M1 • Specification for polished single crystal
associations have workedout
have worked
outsilicon
silicon
purity standards. Among the most wafers
purity standards. Among the most
popular
populararearestandards
standardsofofSEMI
SEMIglobal
global
industry association and JEITA
industry association and JEITA • Jeita EM-3601 • Specification for P-Si for electronic grade
(Japanese
(JapaneseElectronics
Electronicsand
and purposes
Information Technologies
Information Technologies
Association). …and many other standards devoted to the various steps of silicon
Association). processing and production.
35
Silicon – impurities levels
The value chain for the silicon starts with the impure metallurgical silicon and ends at the
semiconductor (or solar) grade silicon
MG-Si EG-Si
The metallurgical silicon contains at least 98% of The electronic grade silicon contains the silicon in
silicon in its volume concentrations between 99.9999999% and
99.999999999% (9N-11Nines)
Concentration Concentration Concentration Concentration

Element (ppm) Element (ppm) Element (ppb) Element (ppb)
aluminum 1000-4350 manganese 50-120

arsenic < 0.001 gold < 0.00001
boron 40-60 molybdenum < 20
antimony < 0.001 iron 0.1-1.0
calcium 245-500 nickel 10-105
boron ≤ 0.1 nickel 0.1-0.5
chromium 50-200 phosphorus 20-50
carbon 100-1000 oxygen 100-400
copper 15-45 titanium 140-300
chromium < 0.01 phosphorus ≤ 0.3
iron 1550-6500 vanadium 50-250
cobalt 0.001 silver 0.001
magnesium 10-50 zirconium 20 copper 0.1 zinc < 0.1
36
Polysilicon production technology -
Technology comparison
37
Manufacturing of polysilicon with Siemens method I
PROCESS OF OF TRICHLOROSILANE MANUFACTURING
In this process, gaseous Hydrogen Chloride is generated by passing Hydrogen and Chlorine through the
generator, after which the gas is dried. The dry Hydrogen Chloride gas is passed through the bed of
Metallurgical Silicon at 300 - 400oC in Hydrochlorination Reactor. Here, the Hydrogen Chloride reacts
with Metallurgical Silicon to form Trichlorosilane (SiHCl3) and Silicon Tetrachloride (SiCl4).
Si + 3HCl -> SiHCl3 + H2

Si + 4HCl -> SiCl4 + 2H2
The outlet gas stream is cooled. The liquid collected from above contains Trichlorosilane (TCS) and
Silicon Tetrachloride (STC). The liquid stream is subjected to fractional distillation to get Pure TCS.
38
Gases processing
HCl is produced via a a H2 +Cl2 reaction . The oversupply of hydrogen is used to

assure the 100% consumption of chloride in the process. Produced hydrochloride
is passed through the absorption, stripper and drying towers. Finally it is
introduced into metallurgical silicon fluidized bed reactors at 300 Celsius degrees
providing TCS.
The reaction gas contains TCS and 10% of STC and is further condensed by cooling
down. Impurities such as boron, phosphorus and carbon are removed during
product distillation. This step is important, because high levels of purity are
required in order to achieve 11 N semiconductor grade silicon. Thus, the
distillation columns are designed to be operated with a high reflux ratio and built
of many trays. In effect, the whole process consumes a lot of energy per unit
weight of product.
39
Manufacturing of polysilicon with Siemens method II
PROCESS OF MANUFACTURE OF POLYSILICON from TCS has two steps
Recovery of gases, purification,

Production of Polysilicon Silicon
recycling.
Trichlorosilane liquid is vaporized. Hydrogen gas is

mixed with Trichlorosilane vapor and fed into the
water cooled Polysilicon reactor. During the
reaction, the Polysilicon gets deposited over the
electrically heated filament kept at 1050o C.
SiHCl3 + H2 -> Si + 3HCl

SiHCl3 + HCl -> SiCl4 + H2
40
Trichlorosilane processing
Hydrogen
H2
TCS
Metallurgical The produced trichlorosilane includes small
SiHCl3 amounts of contaminants and byproducts such
Silicon
as STC. For each mole Si converted to
polysilicon, 3-4 moles of STC are produced.
Thus, the reduction of STC generation is
m-Si important for process efficiency. The produced
STC is further conversed to provide TCS and
direct it back to the silicon production.
The final process of reduction of TCS is
performed with hydrogen at temperatures
near 1000 C, depositing a 99.99…% (in eleven
distributor 9s) pure polycrystalline silicon in rod form
HCl (semiconductor grade).
Gaseous
hydrochloric
acid Si＋3SiCl4＋2H2→4SiHCl3
41
Manufacturing of polysilicon with Siemens method III
Purification and recovery are important stages of silicon production deciding about material properties and overall cost.
RECOVERY STAGE
The reactor outlet gas stream containing Hydrogen, Trichlorosilane (TCS), Silicon Tetrachloride and Hydrogen Chloride
is compressed and passed through metallurgical silicon bed to convert all Hydrogen Chloride gas into TCS. Then the
gas stream is cooled and all TCS and Silicon Tetrachloride are condensed as liquid and recovered.
PURIFICATION AND RECYCLE

The gas stream mainly hydrogen from the scrubbing
system is passed through drying system to remove the
moisture. The pure hydrogen is recycled as feed. The
recovered liquid stream containing TCS and Silicon
Tetrachloride is subjected to fractional distillation to get
Pure TCS. Pure TCS is recycled as the reactor feed.
Silicon Tetrachloride obtained from distillation is
converted into Trichlorosilane by passing Silicon
Tetrachloride vapor along with hydrogen through a bed of
metallurgical silicon in Hydrogenation reactor.
3SiCl4 + Si + 2H2 -> 4Si HCl3
The outlet stream is cooled to condense TCS and un-reacted Silicon Tetrachloride. The liquid stream containing TCS
and Silicon Tetrachloride collected is sent for fractional distillation to get Pure TCS and the gas stream is recycled.
42
Fluidized Bed Reactor
43
Fluidized Bed Reactor (FBR) method
• The raw material for FBR is silane, which can be

prepared by the reaction of magnesium silicide
(Mg2Si) with acids or by boiling TCS - tricholorosilane
(SiCl3H) with catalyst (metal halides like AlCl3). In
effect, the silane and silicon tetrachloride (STC) is
produced. According to the reaction:
4SiHCl3 SiH4 + 3 SiCl4
• The FBR method utilizes the silane (SiH4) or TCS as a

starting material. The main reaction that took place
within reactor is:
SiH4 Si + 2 H2
• Fluidized bed reactor enables very good mixing of

decomposed material and very efficient heat transfer
that is stimulating system conversion. Both factors
influence the process overall efficacy and cost.
44
Fluidized Bed reactor – silicon processing
• Reduced silane produces silicon, which precipitates and generates kernel of deposition
for its vapors. The growth of the particle is controlled by system’s flows. In effect, during
the process granulated form of silicon is produced, which is further utilized for
production of polysilicon chunks.
• Despite of the silane, the FBR process utilizes also TCS (trichlorosilane) SiCl3H via the
process:
4SiCl3H Si + 2H2 + 3 SiCl4
• Silane deposition occurs at 750°C compared to 1100°C for TCS. Thus, Compared to the
other methods FBR comes with lower energy consumption.
• For each mole Si converted to polysilicon even 3 or 4 moles (for Siemens method) of STC
is produced binding large amounts of chlorine and valuable silicon. The FBR process
yields STC (silicon tetrachloride), TCS, DCS (dichlorosilane), and other by-products, which
are separated and purified in a process primarily consisting of distillation. A properly
designed distillation process yields pure TCS for either solar or electronic grade
polysilicon. The by-products DCS, together with STC, can be converted back to TCS.
• Where MGSi is reacted with STC and hydrogen to yield TCS in a FBR operating typically at
elevated pressures and temperature in the range of 500°C. This is an endothermic
reaction, the TCS yield is 18 to 25% depending on the technology used.
45
Fluidized Bed reactor …
• Peak Sun Silicon has developed technology utilizing tribromosilane (SiHBr3) instead of
chloride based chemicals. Their technology utilizes an open-loop, batch, high
temperature process, to a closed-loop (environmentally friendly), continuous, low
temperature process. In this case, the innovation is accomplished by changing the silicon
chemistry from a chlorine base to a bromine base (tribromosilane or "TBS"), and use of a
"fluid bed" ("FB") deposition reactor with continuous recycle of by-products. The
produced silicon will be of 10 N purity level. This process compared to the chloride based
requires lower temperatures and consumes less energy.
46
Byproducts processing.
47
TCS production
The TCS and STC have been produced from direct chlorination process mostly in old type installations.
During this process, the metallurgical silicon reacts with HCl gas at about 300 Celsius degrees and 2-4 bars
and is usually carried in fluidized bed reactors. In next step the TCS is purified in distillation columns.
Chlorination advantages Chlorination disadvantages
•Higher temperature than for CVD

•Low pressure
process
•High TCS efficiency (~ 70-80%)
•High energy losses on cooling
•Low energy purification process
•High yield of STC by product
•STC from CVD process is processed in
•Energetically expensive
additional small system
Production of TCS comes with the fabrication of STC, which oversupply affect the
economic of the whole process. Thus, two dominant technologies were developed to
deal with STC:
•STC converters
•Hydrochlorination
•Redistribution of STC and DCS
48
STC converters
STC converters are getting less popular nowadays. However, there are still plenty of working
installations of this type. The STC converter (hydrogenation) is based on a process described
by reaction:
H2 + SiCl4 HSiCl3 + HCl
Hydrogenation advantages Hydrogenation disadvantages
•Low pressure • High energy consumption

•High purity of produced TCS • Poor reliability of heating system
•Well developed equipment and (expensive failures)
process methodology
Since the beginning of the STC converters these devices have been modernized with regard
to the thermal efficiency and corrosion. However, the heating elements still are a sensitive
part of the whole system and affect the overall efficiency of this system. For STC operating
continuously over years, interruption of the STC supply can create the need to replace these
elements. In effect, this can cost company up to $150000 per occurrence.
49
Hydrochlorination
Hydrochlorination is a process for reduction of STC with hydrogen and metallurgical silicon according to the
following reaction:
3 SiCl4 + Si + 2 H2 4HSiCl3
This process takes place in Fluidized Bed Reactor and at temperatures above 500 Celsius degrees and
pressures higher than 20 bars. The process is continuous and can operate without the shutdowns for years.
During Hydrochlorination a metallurgical silicon can be used as silicon source. The impurities from the
process are fluidized and removed from reaction chamber. This is one of the biggest advantage of the
process comparing to the chlorination, which requires bed dumps every 6-10 weeks.
Hydrochlorination advantages Hydrochlorination disadvantages
•High scaling potential (fluid bed

•Higher temperature and pressures
systems can reach even more than
require more reliable materials and
5000MT per year)
construction of equipment. This
•Lower costs of Off Gas recovery than
implies higher capital cost.
in case of STC converter
•Poor reliability of heating system
•Lower operating temperatures than
(expensive failures)
for converters (i.e. lower electricity
consumption)
50
Silicon processing
51
Wafer production
Production of wafer depends on the specificity of product. Silicon producers are challenged by high
operating costs of this process.
Processing of silicon into wafer
Monocrystalline Multicrystalline
Float Zone Czochralski Directional Ribbon / sheet

method method solidification techniques
The silicon processing and recrystallization depends on the end product requirements.
The solar industry accepts silicon in form of monocrystalline and multicrystalline, while
semiconductor industry is mostly interested in single crystals due to the lower electric
performance of multicrystalline structures. This production step requires significant
amounts of energy, which cost is influencing the final price of produced wafer.
52
Purification (crystallization) methods
Czochralski method
Czochralski method for crystal growing starts with melting the
silicon. Next, a rod with a silicon seed is dipped into the molten
silicon and as it is drawn up. In effect, a molten silicon is
depositing on the solid rod and expands its volume while
solidifying. This method is one of the oldest and simplest in the
industry and provides one of the purest grades of silicon.
However, despite of these benefits, Czochralski method comes
with few technical problems such as long times of operations
and high cost.
Float Zone method

Process for float zone ingot formation is used for producing even
more pure wafers. The biggest advantage of this method is a fact
that the float zone ingot has fewer impurities than a ingot from
Czochralski technique. Comparing to this last method, as with CZ
crystal pulling, a seed crystal is exposed to molten silicon, here,
instead of being dipped into a crucible with a silicon melt, a
heating coil passes along an ingot, effectively separating the
newly crystallized monocrystalline ingot from the input silicon.
In effect, the crystallization process occurs between the solid
and molten regions referred to as the “float zone”
53
Purification (crystallization) methods II
Directional Solidification
In production of multicrystalline silicon directional solidification
technique in used. In this method the multicrystalline blocks are
formed via casting or directional solidification. This process consumes
less time than monocrystalline production, but the structure of the
resultant material is built of variously oriented crystals (domains) and
impurities that influence properties of silicon wafer. The process
takes place in one crucible, which is heated with silicon. Once the
silicon is melted the entire crucible is moved down, away from the
heating element and the silicon solidifies as it cools.
Ribbon / Sheet Technique

In order to reduce the amount of slicing there are various methods
that limits wastes from silicon processing. One of them - the ribbon
technique (Evergreen Solar), utilizes two ribbons of
silicon that are pulled up out of the crucible with molten material.
Once the ribbons are approximately 2m long, they are removed and
sliced into wafers.
Other technique from Schott Solar exploits octagonal hollow tube
that is pulled up from a silicon melt. After 6 m growth, the tube is
removed from the machine and sliced into wafer. This approach was
further modified by introduction of 12-sided (dodecagonal) tube
with better wafer thickness homogeneity than in octagonal form.
54
Polysilicon technology -
Other methods
55
Metallurgical Route: Elkem Route (Norway)
• Metallurgical grade silicon production: Carbon-thermal reduction of quartz in arc furnace

• Slag treatment : High temperature reaction with calcium oxide to remove quartz
• Low temperature two-step leaching: (1) FeCl3 and HCl (2) HF and HNO3.
• Directional Solidification: The upper part is concentrated with impurity and the lower
part is concentrated with highly pure silicon.
• Post treatment: The upper part concentrated with impurity is trimmed.
56
Metallurgical Route: Elkem Route
• Solar grade: 99.9999%

• Solar cell efficiency: 15%-16.5%
• Year 2005 to 2008: pilot scale operation
• Year 2009: nominal capacity of 5000 ton/year
Siemens Route Elkem Route
Production Cost 15-20 USD/kg 5-15 USD/kg
Energy Payback Time 1.6 year 1.1 year
Life Cycle Greenhouse Gas Emission 30 gCO2–eq/KWh 23 gCO2–eq/KWh
• Elkem Route does not involve any energy intensive gas route process step. This gives a
clear advantage of low production cost, low energy cost, and low greenhouse gas
emission.
• Elkem Route cannot yield higher silicon purity than solar grade.
57
Direct Metallurgical Route
• Sintef (Norway) developed SOLSILC Route:

1. Quartz reacts with carbon black (high purity) in plasma furnace:
SiO2 + 2C -> SiC + CO2
2. SiC reacts with quartz in electric arc furnace to yield liquid silicon:
SiC + SiO2 -> 2Si (liquid)+ CO2
3. The residue carbon in the liquid silicon is removed by water vapor in Argon:
C+H2O -> CO + H2
• Wacker Heliotronic (Germany) developed Thermit Reaction Route:

1. With a CaO-SiO2 flux, quartz reacts with aluminum at high temperature:
3SiO2 + 4Al -> 3Si+ 2Al2O3
2. The flux dissolves Al2O3 and silicon can be separated from the flux by gravity.
• Bottleneck of Direct Metallurgical Route:

(1)No cost advantage: 20 USD/kg, compared to Siemens Route 15-20 USD/kg.
(2)High purity grade carbon black or aluminum is difficult to obtain.
(3)The silicon product often contains boron, phosphorous and carbon impurities.
• In the past the Sintef pilot scale was able to produce silicon at capacity 50-100 ton/year
58
Metallurgical Route: Kawasaki Steel Route (Japan)
Directional
Directional Directional
Directional
MG-Si Solidification
PP Removal
Removal BBRemoval
Removal CCRemoval
Removal Solidification SG-Si
Solidification Solidification
• Advantage: simple process,

no by-product.
• Disadvantage: energy
intensive because of the
usage of electron beam
guns and plasma torches .
• In the past, this route
enabled KSR to produce
400 ton Si per year.
59
Fluidized Bed reactor …
• Peak Sun Silicon has developed technology utilizing tribromosilane (SiHBr3) instead of
chloride based chemicals. Their technology utilizes an open-loop, batch, high
temperature process, to a closed-loop (environmentally friendly), continuous, low
temperature process. In this case, the innovation is accomplished by changing the silicon
chemistry from a chlorine base to a bromine base (tribromosilane or "TBS"), and use of a
"fluid bed" ("FB") deposition reactor with continuous recycle of by-products. The
produced silicon will be of 10 N purity level. This process compared to the chloride based
requires lower temperatures and consumes less energy.
60
Analysis of various polysilicon technologies
61
Influence of the Siemens CVD configuration on system’s
productivity
• Kinetic of silicon CVD productivity in various reactor types

production on the
silicon rods is directly
Increase in the production yield [-/-]

100
proportional to the
80 Pressure 1 bar
accessible surface of Pressure 6 bars
its deposition and to Expon. (Pressure 6 bars)
60 Expon. (Pressure 1 bar)
the square of diameter
rod. 40
• Silicon production
yield depends on the 20
concentration of
0
reacting gases 2 4 6 8 12 16 20 30
expressed in reactant Number of rods [-]
pressures. Thus, with
this value increase, the Production of polysilicon has started in 1950 and the size of
silicon deposition rate the CVD reactor has increased from 2 rods (1 hair pin) to
also growth. over 100 for low pressure reactors.
Source: GT Solar, Frost & Sullivan
62
Electricity consumption for various CVD reactors
•Analysis of the production Electricity consumption during CVD process

yield of various CVD reactors
100
provides conclusions that it Pressure 1 bar
product mass [kWh/kg / kWh/kg]

90
Relative energy consumption per

takes more than twice the 80
Pressure 6 bars
energy for the atmospheric 70

reactors to make the same 60
amount of silicon as reactors 50

40
at 6 bars.
30
• Increasing size of the 20
reactors allows for reduction 10
of the electricity 0
consumption due to the fact 0 5 10 15 20 25 30 35
that heat loss per mass of Number of rods [-]
silicon is reduced. (In

Siemens method through the The optimal size of a polysilicon CVD reactor does not
walls of cooled reactors and depends proportionally on the number of rods. It is a optimal
its base part.) However, the balance between maximizing throughput, reducing energy
savings at some scale are not consumption, and minimizing capital cost for the entire
meaningful. plant.
63
Investment cost for CVD facility
•Production of
Investment cost for CVD facility 90 MT per year (Low pressure system)
polysilicon made
225 MT per year (Low pressure system)
from small reactors 230
100 MT per year (High pressure system)
could be less
210
economic than from 200 MT per year (High pressure system)
fewer number of 190

300 MT per year (High pressure system)
large reactors 170 400 MT per year (High pressure system)
•The pressure
$ per kg
150
(concentrations) of
130
the reagents is an
important factor 110
influencing material 90
production costs.
70
This parameter
50
decides on facility
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
performance at its MT per year
various sizes.
64
Hydrochlorination and STC converters cost comparison in
polysilicon production
•The economy of scale Capital cost for various installations

apply to TCS treatment 110
for both production 100 250 MT converters
methods. However, the 90
Average capital cost [$ per kg]

500 MT converters
scaling up is more 80
750 MT converters
beneficial for 70
hydrochlorination plant 60
2 FBR units
(Hydrochlorination)
than for converters 50
system. 40
30
•Scaling up the
20
converters system 0 1000 2000 3000 4000 5000 6000 7000 8000 9000
results in capital cost Installed capacity [per year]
savings. However, the

hydrochlorination plant Cost modeling includes the hydrochlorination FBR, purification of
is less costly even at the TCS and intermediate tanks. In case of converters the system
750 MT per year includes direct chlorination FBRs, converters and purification step.
converters system.
Source: GT Solar, Frost & Sullivan
65
Cost of solar silicon production with various technologies
•Direct chlorination
technology is now being Cost analysis for various PSi production methods
continuously replaced by 1.2
hydrochlorination that affects Overheads

Maintenance and other
the production cost less. 1 Labor
•Fluidized bed technology Energy
comes with various cost Raw materials
savings mostly in energy. 0.8
C o st co n trib u tio n
•The Siemens method could
be made more advantageous 0.6
by application of efficient
heat management system.
The heat form the CVD 0.4
reactor can be recovered for

distillation of TCS, while FBR 0.2
does not include this step.
•FBR provides granulated PSi,
while outcome from Siemens 0
must be crushed to TCS Siemens (HC) TCS Siemens (DC) FBR Silane Silane Siemens
processable form. Method
66
Cost of solar and semiconductor grade silicon production using
various techniques
•Production of solar Semiconductor Overheads, expenses

45
grade silicon can be grade
Depreciation, interests
done using relatively 40 Labor
new FBR silane 35

Steam
Electricity
technique. Raw materials
30
$ per kg of Silicon
• However 25 Solar grade

semiconductor grade
20
silicon requirements
can now be met only 15
with Siemens
10
method and its
derivatives. 5
0
• The Hemlock Conventional Siemens Siemens with Hemlock DCS process FBR silane method
process utilizes DCS hydrochlorination
conversion, what
Siemens method is perceived as reliable source of semiconductor silicon in
puts it in more near future. It must be noted that requirements for solar grade silicon with
advantaged position. regard to purity are increasing and would approach the SEG level.
67
Past Polysilicon production methodology and its future perspective
Since 70ies polysilicon production evolved toward bigger capacities and compact
processes
70ies – 90ies 90ies – 10ies 10ies-20ies

•Size
•Sizeofofthe
thepolysilicon
polysilicon
plant
plant was increasinginin
Plant capacity Plant capacity Plant capacity was increasing
Plant ~ 750 MT per year ~ 2500 MT per year ~ 6500 MT per year time
timesince
since70ies
70iesand
andthis
this
size CVD reactor CVD reactor CVD reactor trend will continue in
trend will continue in
~ 75 MT per year ~ 150 MT per year ~ 350 MT per year future.
future.
•Direct
•DirectChlorination
Chlorination
approach
approachdueduetotothe
thepoor
poor
TCS Direct Chlorination Direct Chlorination Hydrochlorination economic and
economic and
environmental
treatment Hydrochlorination environmentalissues
issuesisis
currently
currentlybeing
beingreplaced
replaced
bybyhydrochlorination
hydrochlorination
•Implementation
•Implementationofof
hydrochlorination
hydrochlorination
STC Non available STC Converters Hydrochlorination
technology
technologyeliminates
eliminatesthe
the
treatment
need of STC converters
need of STC converters
application.
application.
68
Polysilicon production technology. Profiles of
Technology providers (owners) and
Producers.
69
North America Main Polysilicon Technology Providers
Technology Providers Owner’s Technology

GT Solar Hemlock Semiconductor
Dynamic Engineering MEMC Corporation
SRI 6N Silicon
KMPS Wacker Chemie
RMT Mitsubishi Materials
(SUMCO)
REC Group
70
Wacker Chemie
Wacker has five business segments: semiconductors (Siltronic), silicones, polymers, fine chemicals,
and polysilicon. The company has 20 production plants, 14,400 employees, and over 100 Wacker
sales offices worldwide. The polysilicon facilities are located in Burghausen and Stetten.
Company is using traditional Siemens method and FBR to produce PSi. As a starting
source they use TCS. Company claims that TCS is better because it is possible to get higher
yields and they can track this onto their existing supply of TCS which they have at the
plant. At Wacker the fluidized bed reactor are exploited to produce granular high-purity
silicon for high-efficiency solar cells.
Company is doing well and have noticed the 50% of EBITDA in Q1 2010 and the EBITDA
for whole 2010 would be in the range of 40-50%.
Company has tighten its contract policy and now signs agreements for short term silicon
supply (1, 1.5, 2 years).
Its activity is mostly concentrated on the contract sell instead of the spot market. Their
clients are interested on stable source of silicon and seek material of reproducible quality
as from Wacker.
So far, the ramp of their 10000 ton expansion “Poly 8” facility is well on its way and they
expect to finalize the ramp half a year ahead of schedule in the second quarter. This
should result in overall more than 24,000 tons of polysilicon production in 2010, (product
mix between semi and solar). Construction on Poly 9 is progressing as planned, leading
towards a beginning of the ramp of that 10,000 ton expansion in the end of 2011.
In 2009 company has reported sales of 18,100 tons of hyper pure polysilicon.
71
Wacker Chemie
The details of the Wacker’s production are not disclosed and company
keeps the stringent internal policy with respect to know how securing.
Usually, no patenting is applied in the IP securing.
Developed internally technology is applicable for semi and solar silicon
production. It characterizes with high purity level and mature stage of
technology development. However it requires large investments and
comes with high opex.
Rods from siemens method require further crushing, etching and
packaging as well.
The FBR of Wacker is relatively new technology and details of it are

not disclosed. As in the Siemens case, the substrate for reaction is
TCS. The ares of silicon deposition is two orders higher than in case of
Siemens approach and in effect the production yields are bigger.
However, this technology still come with technical problems and
Wacker is one of the few companies that sort them out.
The price target is approximately US$25/kg, based on 500
tonnes/year production, with potential for further price reduction.
Company has patented its technology for silicon packaging and
transportation.
72
REC group
Renewable Energy Corporation's (REC) silicon plant at Moses Lake was started in 2002 by
REC Solar Grade Silicon (REC Silicon). The REC Solar Grade Silicon was a joint venture
between REC group and Advanced Silicon Materials LLC (ASiMl, a subsidiary of the Japanese
industrial group Komatsu Ltd). In this joint venture the ASiMl provided silicon production
plant, which REC Silicon converted into a dedicated plant for solar-grade silicon production
The company has started production has started 3 production facilities in Butte and Moses
Lake. The Silicon III was aimed to allow company to double its polysilicon production from
5300MT (2005 production) to approximately 13000MT with capability of producing 9000MT
of silane gass Company is hiring 500 people and plan to hire more due to the expansion.
REC is producing monocrystalline wafers in its new facility in Glomfjord. Company has also opened production facility in Singapore, which
produces 36% of the solar grade silicon from REC.
REC Silicon is incorporating its proprietary fluidised bed reactor (FBR) technology developed for granular polysilicon production into the
plant. Developed at REC Advanced Silicon Material LLC, the new reactor technology was further developed and commercialized at REC
Silicon, and carries proprietary intellectual property rights. The proprietary production technology has been claimed to significantly reduce
the current capital and operating costs of the plant.
They are using both (Siemens and FBR) silicon manufacturing routes and plan to continue this approach. The Siemens method is the cost
effective solution for semiconductor grade silicon. On the other hand, company has found the FBR technology appropriate for solar silicon
market. Its high volume demand can be fulfilled with the FBR technology.
Recently, REC has faced a problem of lawsuit that seeks to halt the construction and start-up of the $688 million "Silicon IV" chemical
plant. The basis of this lawsuit is the failure of this facility located at Moses Lake to comply with safety and environmental requirements
under the federal Clean Air Act. In addition, the lawsuit alleges a pervasive history of permit violations, chemical releases, fires, and
accidents at the industrial complex owned and operated by Rec Silicon Inc. In the past, the REC struck a deal with Washington State
regulators to expand its industrial complex in Moses Lake without the required environmental permits. The circumstances of this deal are
suspicious and became a subject of the present lawsuit as well.
73
REC group
In the first stage of the manufacturing process, 98% pure metallurgical-grade silicon is
first distilled into silane gas using several distillation processes.
REC has patented (only some aspects) close loop silane manufacturing process that allows
for conversion of mg-Si into TCS and redistribution/distillation into silane. Their process is
continuous and recycles all hydrogen and chloride materials back to the initial reactors,
while continuous destillation steps purify the gas.
Part of the silane gas produced is sold to the manufacturers of thin film solar cells, flat
panel displays and semiconductors, while most of it is used by REC Silicon for in-house
production of solar-grade silicon. Company is providing the silane through the distributors
such as Praxair, Air Liquide, Air products. The cost of the silane varies between 80 to 120
$ per kg depending on the shipment. Company perceives this product as optional source
of incomes to its budget.
Si + 3 SiCl4 4SiCl3H 6 SiCl3H 3 SiCl2H2 + 3 SiCl4

3 SiCl2H2  SiH4 + 2SiCl3H SiH4 Si + 2H2
In this approach, REC has avoided the off gas recovery system and increase the purity of product through using silane to feed their CVD
reactors rather than TCS. Silane can be produced from TCS through a series of redistribution reactors. This process is ideally coupled
with the hydrochlorination process which converts any by-product STC (from hydrochlorination or redistribution) back to TCS.
The decomposition reaction in the Silane FBR CVD reactor is an endothermic reaction and takes place at a much lower temperature than
required for the Siemens TCS CVD. Silane deposition occurs at 750°C compared to 1100°C for TCS. Thus,The Silane FBRdeposition
process saves substantial energy and reduces electric consumption by approximately 70 kWh per kilogram of polysilicon produced.
Further energy savings are realized since there is no need for the large off gas recovery system that is required for TCS deposition. Any
unconverted silane and hydrogen are recycled directly back to the inlet of the silane FBR CV
74
Mitsubishi Materials Corporation
Established in 1950, Mitsubishi Materials Corporation (MMC) is one of the world’s

largest diversified materials companies headquartered in Tokyo, Japan. MMC is a
major supplier of cement, copper, high-tech materials, metal processing, and
electrical materials and components to domestic and global markets including Asia
Pacific, China, Europe, and USA. MMC comprises 221 subsidiaries and affiliates in
25 countries, employing 21,224 people worldwide.
In company’s opinion, after the crisis it will take time to see a complete
recovery in the demand for semiconductors such as 300mm silicon wafers,
but the demand for solar cell-related products remains strong. Furthermore,
since the photovoltaic industry competes for higher energy conversion
efficiency, the supply and demand conditions of high-quality polycrystalline
silicon is expected to intensify. According to MMC, they just increased their
capacity in last year by 1000 ton/year. The current total polysilicon capacity
of MMC is 2800 ton/year, among which 2400 ton is semi-grade, and 400
ton is solar grade. MMC will also promote technical development for a more
efficient production process.
The polysilicon production site of MMC is located in Yokkaichi near Nagoya.
MMC will purchase a new building site and build a new facility near the
existing plant with aim of enhancing the production semiconductor grade
polysilicon up to 3000-4000 ton/year.
75
Mitsubishi Materials Corporation
In the Electronic Materials & Components business, Mitsubishi Materials seeks to turn its silicon operations
into a pillar to secure high profit using a vertical value chain approach. These operations will focus on
polycrystalline silicon, a key material in the production of silicon wafers and solar cells. The Company is also
attracting recognition from makers of semiconductors and high-grade solar cells. MMC also adopts Siemens
methods.
76
Mitsubishi Polysilicon USA
MMC also owns a polysilicon company in USA. Based in Mobile,

Alabama, the plant has an annual capacity of 1800 ton/year,
among which 1600 ton is semi-grade and 200 ton is solar grade.
The plant adopts advanced Siemens methods. CH2M Hill was selected to provide the engineering package
to basically replicate their Yokkaichi plant. The process includes HCl compression, fluidized bed
chlorination, multistage cryogenic condensation, vapor purification by absorption and stripping, multiple
distillation steps, hydrogen gas purification, and electrolytic vapor phase chemical deposition. Subsequent
solid phase product processing, including grinding, and high purity water washing, drying, and packaging
are carried out in a clean room facility.
Process equipment, instruments, and piping

required extreme cleaning measures, including
solvent and acid cleaning prior to erection. Process
materials include metallic silicon, chlorine, hydrogen
chloride, hydrogen, trichlorosilane, silicon
tetrachloride, nitric acid and hydrofluoric acid.
77
SUMCO Corporation
Sumitomo Mitsubishi Silicon Corporation (SUMCO) is headquartered in Tokyo, Japan.

Established in 1999, SUMCO operates 12 manufacturing facilities located in Asia,
Europe and the United States, with 9700 consolidated employees. The major plant in
Japan is in Imari, Saga prefecture.
SUMCO experienced a major downturn in 2009 and is steadily recovering in
2010. Today, the market for silicon wafers for semiconductors is undergoing a
major shift from 200 mm wafers to 300 mm wafers. In response to this
development, SUMCO is reducing the output capacity of 200 mm and smaller
wafers by 20-30%. For 300 mm wafers, production is being concentrated at the
Imari Plant in a bid to create the most competitive manufacturing framework
possible. The current capacity of 300 mm wafers is 14.4 million pieces/year.
SUMCO provides two types of silicon wafers: PV wafer and

Semiconductor wafer. The main manufacturing stages of silicon
wafers include the monocrystalline silicon process ,wafer process, and
epitaxial growth process. All these process are carried out in an “ultra-
clean room” environment with absolute, ensured cleanness. Wafer
diameter ranges from 100 mm to 450 mm.
78
Hemlock Semiconductor
Hemlock has two main business segments: high quality semiconductor and
solar wafer manufacturing. The company has a production plant located in
Saginaw, Michigan and another under construction in Clarksville,
Tennessee, USA, over 1000 direct and contract employees, and 3 Dow
Corning sales offices located in Germany, Japan and Korea.
The Hemlock Semiconductor Group (Hemlock Semiconductor) is comprised of

two joint ventures: Hemlock Semiconductor Corporation and Hemlock
Semiconductor, L.L.C. The companies are joint ventures of Dow Corning
Corporation, Shin-Etsu Handotai and Mitsubishi Material Corporation. Hemlock
Semiconductor began its Michigan operations in 1961 and its Tennessee location
in 2009. The total manufacturing capacity will reach 36,000 metric tons once
Tennessee location was at completely finished by 2012.
Company is using a chemical vapor deposition (CVD) reactor technology process

to produce PSi up to 99.999999999% purity level . The polycrystalline silicon
manufacturing process begins with the silicon-based chemical trichlorosilane,
where high-purity, semiconductor-grade dichlorosilane (H2SiCl2) and
trichlorosilane (HSiCl3) are produced.
These materials are captured and separated

with a large percentage recycled. Additional
quantities are sold to manufacturers for use
in chemical vapor deposition (CVD) of thin
films in electronics applications.
79
Hemlock Semiconductor
Hemlock Semiconductor IP is correlated with 17 issued

US Patents: 7080742, 6605149, 6251182, 5906799,
5851303, 5529935, 5436164, 5422088, 5401872,
5361128, 5232602, 5165548, 5126112, 5118486,
5118485, 5108720 and 5108512, involving
improvements in the whole production chain.
Among the enhancements it could be mentioned a

process for contacting hydrogen gas and TCS in a
reactor comprising a pressurizable shell having located
therein a reaction vessel forming a substantially closed
inner chamber for reacting the hydrogen gas with the
TCS.
The development comprises feeding to an outer

chamber between the pressurizable shell and the
reaction vessel a gas or gaseous mixture having a
chlorine to silicon molar ratio greater than about 3.5.
The process reduces the concentration of hydrogen

and TCS in the outer chamber that results from leakage
of these gases from the substantially closed inner
chamber and the detrimental reactions associated with
such leakage on structural elements and performance
of the reactor.
80
Hemlock process
The high cost of Siemens method effects mostly from high power consumption during
TCS reduction. Hemlock used DCS instead of TCS as material, which may lead to a lower
power requirement for the reduction and to higher productivity.
This process is characterized by; 1) DCS synthesis by TCS redistribution,
2 SiHCl3 SiH2Cl2 + SiCl4
2) Polysilicon formation by DCS reduction in an improved Siemens reactor,
3) Hydrogenation of byproduct STC in FBR.
Conversion efficiency of DCS into silicon is higher than that of TCS, therefore the less
amount of DCS is required. Moreover, the same capacity is required for TCS distillation
as in the conventional Siemens process and additionally to purify DCS for high purity
levels (like for semiconductor silicon). The boiling point of DCS is quite low ( 8.2 C
degrees). Thus, distillation columns should be very efficient.
81
MEMC Corporation
MEMC has seven business segments: Polished, EPI,

Multicrystalline Solar Wafers, Perfect Silicon, Magic Denuded
Zone, SOI and Advanced Materials. Those products, in turn, are
the building blocks for the $1 trillion electronics market (cell
phones, computers, PDAs, CD/DVD players, satellite and
automotive electronics, etc.) and the $18 billion solar cell/module
market (rooftop, solar farms, consumer lighting, etc.). MEMC has
been a pioneer in the design and development of wafer
technologies over the past 50 years, and operates facilities in the
U.S., Europe and Asia Pacific. MEMC’s common stock is listed on
the New York Stock Exchange under the symbol NYSE: WFR and is
included in S&P 500 Index.
MEMC have 10 manufacturing facilities located in St. Peters (Missouri),

Sherman and Pasadena (Texas), Merano and Novara (Italy), Ipoh and Kuala
Lumpur (Malaysia), Hsinchu (Taiwan), Chonan (South Korea), and
Utsunomiya (Japan). In addition, MEMC have 12 sales office in Hillsboro
(Oregon), St. Peters (Missouri), Sherman (Texas), Paris (France), Munich
(Germany), Novara (Italy), Singapore, Kuala Lumpur (Malaysia), Shanghai
(China), Hsinchu (Taiwan), Seoul (Korea) and, Tokyo (Japan).
MEMC have a Market Capitalization of $4.4 billion, an Average Daily Volume

of 7,137,175, and Revenues of 21% CAGR, at Q1 2010. Company has stable
contract policies with signs agreements for short and medium term silicon
supply. Clients are interested in its international representation, flexibility
and high quality products.
82
MEMC Corporation
MEMC Corporation have 20 issued US

Patents: 7559825, 7137874, 6712673,
It must be noted that the MEMC production
6649883, 6515742, 6514423, 6479386, utilizes the Czochralski method of growing single-
6214704, 6200908, 6189546, 6135863, crystal silicon ingots. In broad terms, a seed
6114245, 5980629, 5976247, 5837662,
5770522, 5632666, 5605487, 5439523 and crystal is dipped into molten silicon, and then
5340437, 5 issued European Patents: slowly pulled out while the temperatures and
EP0748885B1, EP0753605B1, EP0673545B1,
EP0753605A1 and EP0748885A1, 5 US Patent
speeds are accurately monitored and controlled.
Applications: US20090199836, The resulting ingot is a single, uniform crystal of
US20080153391, US20060005761, silicon with minor impurities included (the
US20040038544 and US20030064902, and 17
WIPO Patent Applications: dopant).
WO/2009/102630A1, WO/2003/028951A1, However, the silicon single crystals grown by the
WO/2002/069391A1, WO/2002/066967A1,
Czochralski process can contain microdefects
WO/2002/042033A1, WO/2002/011947A2,
WO/2001/063656A1, WO/2001/060567A1, formed by the agglomeration of vacancies and
WO/2001/049450A1, WO/2001/011671A1, self-interstitials.
WO/2000/062977A1, WO/2000/047369A1,
WO/2000/036637A1, WO/1999/031724A1,
In this regard, company have developed various
WO/1999/009588A1, WO/1995/031309A1 own techniques in order to solve this and other
and WO/1995/010850A1, silicon related problems.
involving improvements in polysilicon
manufacturing.
83
MEMC Corporation
Below: company’s materials presenting silicon processing.
Crystal Growth Wafer Slicing Wafer Polishing Wafer Cleaning Epitaxial Deposition
84
Dynamic Engineering
DEI engineers proprietary equipment and plant design for the production
of silane, trichlorosilane (TCS), STC and polysilicon for the solar,
semiconductor and electronics industries. The company have three main
segments: solar, semiconductors and pharmaceuticals. It is located in
Houston (TX). DEI processes look for low-costs with the highest possible
conversion of mgSi to high purity polysilicon, and rapid time between
mechanical completion and production product to meet the required
specifications.
The provided technologies include:

Distillation and Purification: final purification of solar and electronics grade TCS by
removing impurities below the ppb level, through multiple distillation columns.
TCS Fluidized Bed Reactor Design: FBR performs in a pressurized and kept to a uniform
temperature distribution that maximize the yields of TCS.
By Product Catalysts: redistribution catalyst to minimize the production of DCS and STC and
maximize the yield of TCS.
Silane Option: a unit operation for the production of silane can be used by specifying
different operating conditions and reactor design for the redistribution catalyst. Electronics
grade silane can be produced for approximately $25/kg.
Polysilicon Plant Integration: integration of different units from all process providers,
including Metallurgical Grade silicon grinding, HCl preparation
CVD Reaction, STC Converters and Gas recovery, Utilities, Overall control
It should be treated also as EPC company
85
Dynamic Engineering
DEI has 10 patents in the United States pertaining to Optimization for final purification of TCS & STC to insure
the processes for preparing high purity contaminants can be reduced to the parts-per trillion level.
trichlorosilanes from the by-products of the primary Dynamic process model considers over 300 chemical species
reaction in the refinement of polysilicon. This in the purification process, allowing for the highest purity
proprietary process increases the product recovery TCS without significant loss of chlorosilanes.
and is estimated to be worth a minimum of Fluidized Bed Reactor design incorporates over 100
$15,000,000 US Dollars per year from a 3,000 ton combined years of experience in design and operation of
per year polysilicon plant. FBRs in TCS production facilities to provide highest
conversion to TCS with minimal loss and reduced
Some of them are: 7754175, WO/2009/029794A1, maintenance.
WO/2009/029791A1, EP0601527B1, EP0299436B1.
Redistribution Reactor design allows for elimination of waste
Dichlorosilane through reaction with STC to produce TCS,
both improving process yield and reducing the cost of
converting STC to TCS in the Hydrogenation Converters.
mgSi grinding technology which allows for use of lower cost
lump silicon, reduces bulk contaminants, and produces a
particle size optimized for the chlorination reaction. The
optimized particle size allows for reduction in byproducts
and waste.
Other solutions of DE :
Process for reactive distillation of Silanes.
Zero Heat Burder Fluidized Bed Reactor for
Hydrochlorination of STC and MgSi.
86
KPMS
KMPS is located in Paramus, New Jersey, and the pilot plant facility is
located in Houston, Texas. KMPS has over 50 employees.
It is a joint venture with Koch Industries – global company, and parent
company of Koch-Glitsch LP, one of the world’s most prominent
suppliers of mass transfer equipment.
Koch Modular Process Systems, LLC. (KMPS) specializes in ten business

segments for the design and supply of modular mass transfer systems:
Chemical, Photovoltaic & Polysilicon, Alternative Energy, Pharmaceutical,
Petrochemical, Biotech, Biochemical, Food and Flavor & Fragrance.
KMPS used to partnering with customers to implement new and developing
technologies to take them from concept to commercialization.
It offers services in such areas:

•STC to TCS Conversion
•Polysilicon Production (including fluidized beds)
•Waste STC Hydrolysis
•Low Energy Purification Techniques
They have industrial experience with various players globally.
87
RMT
RMT is a leading Technology License provider that supplies a

complete polysilicon plant design for solar grade and
electronics grade silicon. An RMT designed polysilicon plant
is comprised of the following technologies that generate,
store, and react TCS and STC.
RMT provides the polysilicon plant technology license “how

to” as a basic design package (BDP). RMT recommends a
feasibility study to determine the best approach to the
project. Their services include :
Low Pressure Chlorination (optional) – uses the reaction of hydrogen chloride and metallurgical grade silicon to generate TCS.
Hydrochlorination – uses the reaction of STC, hydrogen and metallurgical grade silicon to generate TCS.
Distillation – separates the impurities such as boron, arsenic, carbon, iron, and phosphorous to produce high purity TCS.
DCS Conversion (optional) – Disproportionation technology to convert the byproduct DCS stream to TCS.
Tank Farm – chemical storage.
Reduction – uses Siemens reactors fed with purified TCS to produce high-purity silicon rods for use in the solar and electronics
industries.
Hydrogen Recycle – recovers hydrogen from the Siemens reactor exhaust gases and returns it to the CVD reactors. The
chlorosilanes are sent to distillation and the HCl goes to chlorination.
Finishing – prepares the silicon rods for packaging and shipment.
Laboratory – analyzes process and silicon samples to verify purity specifications and process stream conditions.
88
SRI
SRI International is an independent research and technology development organization with headquarter located
in Silicon Valley.
The nonprofit institute performs sponsored research and development

for government agencies, businesses, and foundations. SRI also licenses its technologies, forms strategic alliances,
and creates spin-off companies. In 2008, SRI’s consolidated revenues, including its wholly owned for-profit
subsidiary, Sarnoff Corporation, were approximately $490 million.
SRI International claims that developed a novel production process for manufacturing solar-grade silicon that
works at a half the cost of Si produced using Siemens Process, with <0.02 ppm of impurities, suited to use in single
crystal, polycrystalline, or silicon film ribbon production, and able to work for large-scale production with much
lower CapEx than required for a Siemens-type plant.
SRI’s bench-scale reactor has produced 4.0 kg Si/hour (equivalent to 10-15 tonnes/year). SRI has designed a
production reactor for 1000 tonne/year. The average construction schedule :
• Months 0 to 6: transition technology and design pilot plant (~25 tonne/year).
• Months 6 to 18: start-up pilot plant; expand design to 1000 tonne/year plant.
• Months 18 to 36: build 1000 tonne/year plant.
SRI works with its licensing partners to transfer the technology. SRI has entered into several licenses for its silicon
production process and intends to expand its activities in this area by entering into additional licenses. Potential
partners include established and new silicon producers, solar cell makers who need a reliable, low-cost internal
source of silicon, chemical companies that want to enter the solar silicon supplier market, and entrepreneurs.
89
OCI
OCI is a Korean chemical company providing inorganic chemicals,

petro and coal chemicals, fine chemicals, insulation materials and
polysilicon products to global market. Founded in 1959, OCI is
headquartered in Seoul and sales office worldwide. Currently
there are 2487 employees.
Although OCI’s polysilicon product is applied in solar PV industry,
its purity can actually reach semiconductor grade (10N-11N). OCI
adopts Siemens technology for the production.
OCI has ambitious plans in terms of rapid capacity expansion. With its own Siemens technology, the
company’s capacity of polysilicon increase from 6,500 ton/year in 2009 to current 17,000 ton/year
and by the end of 2011, as the phase 3 construction in Gunsan factory involving 188 million USD
investment is complete, the capacity is expected to reach 32,000 ton/year, which would make OCI the
second largest polysilicon manufacturer in the world.
It is established that the current overall polysilicon capacity is oversupplied. Nevertheless, OCI
believes that their higher purity and higher quality polysilicon product will make the difference to
survive in the global market, by long-term contract with partners at a steady price. Currently their
technology is focusing on driving cost down through operational excellency and technology innovation.
OCI has plan for downstream integration to expand the market and to achieve world grid parity.
90
6N Silicon
6N Silicon base its business in the production of solar grade polysilicon for solar
industry. The company is a subsidiary of Calisolar, a company focused in solar cells
production, located in California. 6N Silicon is located in Toronto area, Canada.
6N has benefited from access to considerable industry experience in processing

other metals and applying collective skills to refine the 6N solution. The company
has developed a proprietary process for purifying inexpensive, readily available
metallurgical grade silicon into solar grade silicon using low cost metallurgical
processing. 6N's silicon purification process provides a revolutionary approach to
the production of solar grade silicon for the photovoltaic industry.
The company leverage its knowledge from much larger metal processing industries, allowing the use of warehouse-
type facilities in convenient locations. This is a considerable advantage over the highly specialized industrial plants
with large settling ponds that span across many hectares in isolated locations that are required for other
approaches. The EOS Project
This is a multi-year funded industry collaboration to speed the development

and adoption of the innovative 6N process. The primary focus of the EOS
Project is the commissioning and operating of a pilot line that will refine,
demonstrate and validate the 6N Silicon purification process.
The EOS Project has been facilitated through the support of Sustainable
Development Technology Canada (SDTC) not-for-profit corporation created by
the Government of Canada and the Government of Ontario's Innovation
Demonstration Fund.
91
GT Solar
GTSolar has three main business segments: polysilicon production

equipment, thrichlorosilane (TCS) and silane production packages, and
photovoltaic production equipment, in addition to project service and
support engineering. The company has a plant located in Missoula,
Montana, representative offices in USA (MT, NH), China and Taiwan, and
sales partners offices in Germany (GS Electronic), India (International
Marketing Corp.), Italy (S Technologies), Korea (AMC Corp.), Middle East
and Africa (Kanaan Energy Solutions) and Russia (I&I Consulting).
The company have 325 employees. NASDAQ: SOLR.
GTSolar revenues reach the $138.5M, $173.6M and $194.7M for Q42009
and expected Q3 and Q42010 respectively. Gross margins rise up 28.5%,
44.2% and 37.5% and operating margins 15.3%, 33.2% and 28.4% at the
same periods.
GTSolar worked for the following companies:

Nitol Solar, previously the Nitol Group, an independent polysilicon producer based in Russia. The company is installing GT
Solar’s polysilicon reactors and silicon tetrachloride converters in its production facility near Irkutsk, Siberia. Nitol is expected
to become the largest silicon producer in Russia.
Soltech, S.A., based in Patras, Greece, will use a GT Solar turnkey solution, extending from wafers to modules, to become the
first fully-integrated PV producer in the Southern European market.
OCI, a leading Korean chemicals producer, is using GT Solar’s 48-rod chemical vapor deposition (CVD) polysilicon reactor to
manufacture polysilicon in its Gunsan, South Korea facility.
Nexolon, headquartered in Seoul, Korea, is using GT Solar’s GT-DSS450™ furnaces to manufacture multi-crystalline ingots and
wafers in its newly-constructed Iksan Industrial Complex in Korea.
92
GT Solar
93
GT Solar
Company’s patents are devoted to the adjustment of polysilicon production technology.
GTSolar have 2 issued US Patents: 7540919 and Improved production of polysilicon by chemical vapor
7175685, 2 European Patent Applications: deposition (CVD) where conventional silicon "slim
EP2013376A2 and EP1257684B1, 5 US Patent rods" are commonly used in Siemens-type reactors by
Applications: US20090206233, US20080295294, replacing them with shaped silicon filaments of similar
US20070251455, US20070148034 and electrical properties but larger surface areas, such as
US20060219162, a Japanese issued Patent silicon tubes, ribbons, and other shaped cross
JP2009298693, and 16 WIPO Patent Applications: sections.
WO/2010/008477A2, WO/2010/008477A3,
WO/2010/005705A1, WO/2009/120862A2,
WO/2009/120862A3, WO/2009/120859A1,
WO/2009/117545A1, WO/2008/150984A1,
WO/2008/089472A1, WO/2007/127657A2, Arranging heating element techniques in a crystal
WO/2006/107769A2, WO/2003/059570A1, growth apparatus connecting elements such as heater
WO/2002/060620A1, WO/2002/040732A1, clips used to interconnect one or more heating
WO/2002/040183A1 and WO/2002/040182A1, components of the heating element, and to connect at
involving different equipment designs and least one of the heating components with the crystal
improvements for polysilicon manufacturing. growth apparatus. The heating components can be
The company position in the market is built on the electrically and thermally coupled, and can be
base of the optimization of the process ensuring connected via the same circuit, in order to simplify
quality and reducing costs and energy. control of the heating element.
94
Centrotherm
Centrotherm photovoltaics AG is one of the world's leading suppliers of process

technology and key equipment for the production of solar silicon, solar cells and
solar modules. Company headquarters are in Blaubeuren, Germany (Baden-
Württemberg). However, it has several offices and technical facilities across the
world.
Centrotherm was founded in 1976 as “centrotherm Elektrische Anlagen GmbH +
Co. KG. „ . In 1990 it was split into two branches, one of them refers to the
photovoltaic, second to the clean solutions. As the photovoltaic branch develops,
manufactures and markets turnkey production lines, key equipment and process
technology for the production of polysilicon and solar cells as well as crystalline-
and thin film solar modules and also provides a range of related services to
customers.
In 2009 company has reached more than 500 000 Euro revenues with EBITDA
increase by 1.9% comparing to the 2008.
Company handles the silicon technology starting from planning of silicon factories, on to engineering through
silicon equipment as well. In effect, company is well oriented in providing technology expertise for practically
each of silicon value chain. In 2010 company plans to strengthen its R&D activity by investing 50 mln euro in
R&D programs devoted to the not only silicon production, but also to the thin film solar cells production.
As technology providers company is supporting its client in facilitating the silicon production across the world.
In this case, company offers its expertise and equipment suitable for production of high purity silicon for solar
industry needs.
95
Other polysilicon producers
96
GCL-Poly
Establlished in 2007, GCL-Poly is largest polysilicon and wafer supplier in

China, delivering high quality and low cost silicon products to the solar
industry. GCL-Poly is also a top green energy supplier in China, providing
power and heat in an efficient and environmentally friendly way via
cogeneration, biomass, incineration, wind and solar. Headquartered in
Hong Kong, GCL-Poly achieved explosive expansion through M&A, and
established long-term contracts with downstream manufacturers. GCL-
Poly currently comprises 21 subsidiary and associated power plant, hiring
4162 employees nationwide.
The current polysilicon capacity is 21,000 ton/ year, six 9 solar grade. GCL-
Poly plans to upgrade the manufacturing system to produce semi grade
polysilicon in the future. GCL-Poly adopts advanced Siemens method, and
their technology provider is the US company CDI and Dynamic Engineering
Inc. Most of the polysilicon production is supplied for domestic market.
The current wafer capacity is 1200 MW, and aims to reach 2000 MW in the
end of 2010. the wafer facilities adopts the world's most advanced wafer
devices, including GT Solar's latest multicrystalline ingots furnaces and
Meyer Burger's latest wire saws, and has fully-automatic cleaning and
testing functions.
Both facilities are based in Xuzhou, Jiangsu Province. The biggest PV power
plant (20 MW) in China is also constructed by GCL-Poly in Xuzhou.
97
Silfab
Silfab is vertically-integrated PV technology solution provider founded by a team of

partners with thirty years of experience in the solar business.
Silfab planned in the past to facilitate production of silicon of purity of 9N, but the facility
has not started yet. They are targeting the solar market with this purity level. In their
opinion this level of purity is highly required by customers from solar industry. The
semiconductor industry will use mostly 11 N purity grade silicon instead of less pure
material.
Projected production capacity is approximately 5600 MTY (two production lines of 2800 MTY). Company is
now at the phase of completing preparation tasks. Once they launch the installation, they will produce silicon
with the 9N purity level, which will be used for their own purposes. The Silfab is covering wide range of solar
systems value chain ranging from metallurgical silicon up to pv systems. Its share capital is 90 millions euro
and company estimates to generate revenues this year up to 70 millions euro.
Its acitivity is mostly concentrated on vertical integration of pv system production. They developed their
“Green-to-Green” manufacturing model that spans the entire PV value chain, from polysilicon to modules, and
is designed to cut as much waste and CO2 sources while using the least amount of energy and raw material.
Some of the processes are energetically demanding like production of polysilicon. In this order company
located their facility in close neighborhood of hydroelectric power plants.
98
OCI
OCI is a Korean chemical company providing inorganic chemicals,

petro and coal chemicals, fine chemicals, insulation materials and
polysilicon products to global market. Founded in 1959, OCI is
headquartered in Seoul and sales office worldwide. Currently
there are 2487 employees.
Although OCI’s polysilicon product is applied in solar PV industry,
its purity can actually reach semiconductor grade (10N-11N). OCI
adopts Siemens technology for the production.
OCI has ambitious plans in terms of rapid capacity expansion. The capacity of polysilicon increase from
6,500 ton/year in 2009 to current 17,000 ton/year and by the end of 2011, as the phase 3
construction in Gunsan factory involving 188 million USD investment is complete, the capacity is
expected to reach 32,000 ton/year, which would make OCI the second largest polysilicon
manufacturer in the world.
It is established that the current overall polysilicon capacity is oversupplied. Nevertheless, OCI
believes that their higher purity and higher quality polysilicon product will make the difference to
survive in the global market, by long-term contract with partners at a steady price. Currently their
technology is focusing on driving cost down through operational excellency and technology innovation.
OCI has plan for downstream integration to expand the market and to achieve world grid parity.
99
Tokuyama Corporation
Tokuyama Corporation is a chemical manufacturer based in Japan. Headquartered in

Tokyo, Tokuyama Group has branched all over Japan, and operations in US, Europe,
Singapore, China, and Korea. The four business divisions are: Chemicals, Specialy Products,
Cement, and Advanced Materials.
After the recession in 2008, in 2009 the company achieved a return on equity (ROE) of
3.5%. The ROE is expected to grow up to 6% in 2010.
Tokuyama is a major semiconductor grade polysilicon supplier for the global market. The current total
polysilicon capacity of Tokuyama is 8200 ton/year, among which 5700 ton is semi-grade, and 2500
ton is solar grade. The demand driver for semi-grade comes from digital consumer electronics such as
PCs, cell phones, digital cameras, DVD recorders, and flat-panel TVs. On the other hand , in the
growing field of solar cells, customers are demanding lower-cost materials to further proliferate. In
response to these demands, Tokuyama is advancing R&D of new vapor to liquid deposition (VLD)
production technologies that dramatically improve efficiency over current production methods for
polysilicon for solar cells. Besides Polysilicon, Tokuyama also produces and supplies TCS.
100
Tokuyama Corporation
Tokuyama adopts Siemens methods

to produce semi-grade polysilicon.
TCS is produced from metallic
silicon and purified by distillation
refining. Reduction is performed
with hydrogen at temperature 1000
degree C. depositing an eleven-9
pure polysilicon in rod form.
Tokuyama revealed that their technology provider

is an American company, but refused to provide
further information.
101
Recommendation and analysis of provided
equipment
102
Poly Plant Project, Inc
Founded in 2005, Poly Plant Project (PPP) is based in California and has offices in US, Italy, Dubai, China,
Korea, Japan. It is a technology provider for the polysilicon industry worldwide. Most of PPP’s project is
from international market, e.g. Spain, Norway, Italy, Russia, Saudi Arabia, Qatar, Dubai, China, Taiwan,
Korea, Japan and US.
PPP provides customized consulting, engineering, process technology and equipment, modular packages
such as the systems required to produce and purify trichlorosilane (TCS) as well as complete plant
solutions based on its advanced and proven process technology and equipment designs. Their solutions
enable the customers to build, startup and safely operate efficient and reliable poly plants that deliver
attractive Capex and minimized Opex. Their focus on reducing operating costs enables poly plant owners
and investors to maximize profits from the continuous reliable production of low-cost, high-purity
polysilicon.
In addition to providing poly plant engineering design, PPP offers pre-construction consultation services
and reports, which detail plant site requirements, engineering and construction issues, production
processes, process and products evaluation, operator and safety training, plant start-up, safety systems
as well as cost estimates for the engineering services (plant design), and key technologies needed to build
a polysilicon production plant.
In addition, investors and companies considering building new plants or expanding or improving existing
polysilicon production plants are supported also by PPPs with advanced process technology and
equipment, plant worker and safety training, plant and equipment commissioning and startup support as
well as plant maintenance and troubleshooting and other plant-specific services.
103
CVD Reactor of PPP
36-L CVD Reactor

Poly Plant Project’s 36-L Reactor is the market leader in output,
production capacity and efficiency for 36 rod (18 pair) CVD Reactors.
PPP’s 36-L CVD Reactors deliver a minimum annual production capacity
of 200 Metric Tons per Year (MTY) of high-purity polysilicon. The 36-L
CVD Reactor is a high-efficiency unit, consuming less than 70 kWh of
electricity per kilogram of polysilicon. PPP’s CVD Reactors operate
safely and minimize the consumption of electricity delivering the
lowest possible operating costs thereby reducing the cost of each
kilogram of polysilicon produced.
54-R CVD Reactor

Poly Plant Project’s 54-R Reactor is the market leader in output,
production capacity and efficiency for 54 rod (27 pair) CVD Reactors.
PPP’s 54-R CVD Reactors deliver a minimum annual production
capacity of 365 Metric Tons per Year (MTY) of high-purity polysilicon.
The 54-R CVD Reactor is a high-efficiency unit, consuming less than 56
kWh of electricity per kilogram of polysilicon. PPP’s CVD Reactors
operate safely and minimize the consumption of electricity delivering
the lowest possible operating costs thereby reducing the cost of each
kilogram of poly produced.
104
TCS Synthesis Equipment System of PPP
PPP provides a complete high-efficiency Trichlorosilane (TCS)

Synthesis System for polycrystalline silicon production plants.
The steps that are involved in the generation of TCS liquid for
purification are: Generation of TCS production gas, quenching of the
TCS production gas, condensation of TCS production gas and
stripping of crude TCS liquid.
The following sub systems are required to generate TCS liquid for
purification:
- Anhydrous HCl generation and feed system
- MGSi conveyance and feed system
- Fluidized bed reactor (FBR) and components
- FBR oil system for heating and cooling
- TCS quenching, condensation and stripping system
- TCS production waste recovery system
PPP is capable to design, fabricate and commission major
equipment for TCS Synthesis and provide all of the TCS Synthesis
System when PPP is providing its Complete Plant Solution.
105
STC-to-TCS Converters of PPP
STC-to-TCS Thermal Converters are critical equipment required in polysilicon

production plants. These Converters are large pressure vessels with bell shaped
(“bell jar”) enclosures that sit on top of base plates.
The Thermal Converter system turns recovered silicon tetrachloride (STC) back
into useable TCS by exposing the STC to high temperatures in the presence of
hydrogen. The Thermal Converters are designed to contain the pressure and
high temperatures that occur during the STC-to-TCS Thermal Conversion.
High Efficiency Polysilicon Production

PPP has designed high efficiency Thermal Converters to operate consuming the
least amount of electricity, which lowers operating costs, reducing the cost of
each kilogram of TCS produced.
PPP provides two different models of STC-to-TCS Thermal Converters designed
to fit our customers’ plant. Both models of Thermal Converters provide 20% or
higher single pass conversion of STC-to-TCS.
Flexibility of Use
PPP’s Thermal Converters use the same pressure vessel as PPP’s CVD Reactors. This makes it possible to use
Thermal Converters in-line with the CVD Reactors. With only minor changes, a Thermal Converter can be
changed into a CVD Reactor. PPP has changed a number of Thermal Converters over to CVD Reactors. This
flexibility enables customers to quickly and easily change and expand their plants with little cost impact
when adding Cold Conversion.
106
Cold Conversion Equipment of PPP
Cold Conversion Equipment
In the trichlorosilane (TCS) production and deposition processes, significant quantities of co-product
silicon tetrachloride (STC) are generated. The STC must be recovered, converted to TCS, and recycled
to make the polysilicon production process cost-effective. There are two production technologies for
conversion of STC to TCS: the thermal process operating at ~1200 C°and the hydrogenation (cold
conversion) process operating at ~500 C°.
PPP supplies process technology and equipment for both processes. The cold conversion process was
developed by PPP in response to the abundance of STC in China and the difficulties of obtaining
anhydrous HCl at some plant sites. This advanced process has higher STC to TCS conversion than the
thermal process.
In addition to the process technology, Poly Plant Project, Inc. (PPP) has developed the key equipment
for the Cold Conversion technology; the advanced Fluidized Bed Reactor (FBR) for the hydrogenation
of STC to TCS. This technology was developed by PPP’s experts to meet performance, operability, and
maintainability requirements, using high pressure and lower temperature operating parameters, with
higher conversion of STC.
Combined with PPP’s separation/purification system, the TCS produced from cold conversion is very
cost competitive with respect to both CAPEX and OPEX compared to hydrochlorination TCS production.
PPP provides the Cold Conversion FBR and settler equipment.
107
Other Equipment of PPP
Distributive Control System (DCS)

PPP provides the complete Distributed Control System (DCS) solution for the Reactors and Converters.
The DCS is a process automation system specifically designed to meet the requirements of the PPP
process technology package. The PPP DCS represents the state-of-the-art in automated control and
plant-wide process management.
PPP provides systems for the CVD Reactor Building and DCS Off Gas Recovery and DCS System for the
TCS Production, Distillation, and Utilities Systems. These two systems may be integrated into one
overall system.
Fluid Delivery System (FDS) for Reactors and Converters

The FDS consists of control valves, instrumentation, and piping used to monitor and control the
process streams supplied to the Reactors and Converters. The small size of the FDS allows for efficient
modular process integration while providing ease of use and serviceability to all instrumentation and
valves.
Vent Gas Routing (VGR) System for Reactors and Converters
PPP-E offers a VGR system to control the process streams leaving the Reactors and Converters. Similar
to the FDS, the VGR also provides customers with a modular skid mounted design that allows for ease
of installation, operation, and serviceability.
108
Other Equipment of PPP (con’t)
Silicon Rod Harvester

One of the most critical equipment in polysilicon product handling process is the product harvester,
which is used to harvest deposited polysilicon rods from the reactor after every deposition cycle. PPP
has developed its own highly sophisticated product harvester
Filament Production System
PPP offers a seamlessly integrated solution for filament production meeting the plant’s annual
demand for polysilicon production. PPP’s offering includes the following:
-Fully integrated technology package, providing complete engineering, design and process
information required to produce polysilicon filaments and bridges for polysilicon production
-Complete plant and equipment layout design
-Supply of all major equipment including Czochralski pullers, polysilicon rod cropping machine,
filament cutting machine, filament and bridge grinding machines, etching/cleaning bench, annealing
furnace and other associated equipment
-Equipment installation support
-Commissioning, startup and training support
-Equipment servicing and maintenance
109
Centrotherm
Centrotherm photovoltaics AG is one of the world's leading technology and equipment providers for the
photovoltaics sector. With more than 30 years of experience and an extensive, proven technology platform
on almost all levels of the photovoltaic value chain, the company sees itself as a pioneer in the industry. Its
strengths include the development of new technologies and innovations and their implementation in
modern production systems and efficient processes.
Centrotherm’s business activities at a glance:

- Feasibility studies and business plans to install and operate silicon factories
- Planning of silicon factories including the design of production layout
- Consulting on the design of building services engineering, in particular for the supply of electricity,
process gases, water and other media (facility engineering)
- Delivery and assembly of production equipment for the manufacturing of silicon on location, including
the monitoring of the installation process, the final inspection and commissioning of production
equipment and facilities
- Ramping up production equipment and hand-over to the customer with the guaranteed performance
parameters for required products, such as production capacity and energy consumption
- Implementation of stable quality management systems
- Training of customer employees for production equipment operation
- Delivery of required spare parts ensuring the ongoing operations of the production location
- Inspection of production equipment for quality assurance in the ongoing production process
- Supplementary services and consulting for established and future silicon manufacturers
- Joint development of maintenance concepts for our production equipment and plant
110
Centrotherm’s Equipment
CVD reactor
centrotherm has developed and constructed a CVD reactor for industrial
silicon production. In the chemical vapor deposition process, silicon is
deposited from the gas phase. Hydrogen (H2) and ultra-clean trichlorosilane
(TCS) are used as precursors which react to deposit silicon under high
temperatures and high pressure.
Improved design/engineering
Proven process/technology
Low energy consumption: < 90 kWh/kg
High capacity: up to 170 metric tons/year
Lab CVD reactor

The miniature version of the CVD reactor is an ideal analysis tool for silicon
quality control. The reactor is also an excellent training tool for the CVD process.
It is a very popular product as it is easy to use and highly automated.
Operating pressure according to execution: 0.3 - 0.7 bar or 1.0 - 7.0 bar
Trichlorosilane consumption: 20 kg/cycle
Duration of deposition process: 12 - 14 hours
Total duration of cycle: 16 hours
111
STC-TCS converter
In addition to CVD-reactors centrotherm also supplies STC-TCS converters. They
transform the silicon tetrachloride produced in the CVD process into
trichlorosilane, which in turn is recycled into the process. Silicon production
costs are significantly reduced thanks to the recovery of trichlorosilane.
High conversion efficiency per cycle >16%
High gas throughput: 3000 kg/h
Multi-crystalline ingot furnace

The centrotherm multi-crystalline ingot furnace is designed for the production
of multi-crystalline ingots from polysilicon pieces by directional solidification
based on the vertical gradient-freeze method. The multi-crystalline ingot
furnace consists of a stainless steel vacuum vessel with integrated water
cooling. It contains an electro-mechanical opening and closing mechanism and
comes with an integrated crucible loading tool. For process control it is fully
automated and includes two independent adjustable heating zones.
112
Vent gas recovery system

Centrotherm vent gas recovery system (VGR) Centrotherm’s Virtual Polysilicon Factory
is used for the treatment of both reactor and
converter vent gas streams. TCS
The VGR consists of a main process area with
distillation columns and condensation units,
supplied by a compressor unit and a
refrigeration unit. The basic design already CVD
includes enhanced condensation capacity
and separate condensate tank for converter
quench gas stream.
Ultra-low temperature processes are applied

to achieve highest recovery rates for all
compounds of the vent gas stream
Vent Gas
HCl buffer tank can be included to adjust HCl
supply pressure and flow to actual needs of
associated units.
Quality Control
113
List of EPC/EPCM contractors and their
profiles
114
Fluor
Fluor (NYSE: FLR) has five main business segments: Energy &
Chemicals, Industrial & Infraestructure, Government (mainly
environmental projects), Power and Global Services. Belonging
to the first, Fluor dedicate a business line to global engineering,
procurement, construction and maintenance (EPCM) and
project management in the polysilicon marketplace.
Their project’s capabilities include the entire value chain:

program management, site selection, TCS and polysilicon
integration, manufacturing design-build for ingots, wafers, and
cell production, worldwide EPCM, operations and maintenance.
So far, the technologies facilitated by Fluor comprise: integration of existing TCS and Siemens processes for
producing polysilicon, timely scale-up and commercialization of emerging technologies, engagement in
polysilicon production via the metallurgical route.
The company’s headquarter is located in Texas, but Fluor has 19 offices in USA, 3 in Canada, 7 in Latin America, 4
in Eastern Asia, 3 in South-Eastern Asia, 2 in Southern Asia, 3 in Middle East, 12 in Western Europe, 2 in Eastern
Europe, 3 in Australia and 1 in South-Africa.
Fluor has more than 36,000 global employees deployed on projects in 66 countries and 24/7 project-execution
capabilities.
115
Fluor
Engineering Procurement
•• Traditional
Traditionaldisciplines:
disciplines:architectural,
architectural,civil,
civil,electrical, •• Fluor
electrical, Fluormanages
managesnearly
nearly$12
$12billion
billionininequipment,
equipment,
mechanical, piping, and structural engineering. materials,
materials, and services through strategicsourcing,
and services through strategic
mechanical, piping, and structural engineering. sourcing,
•• Advanced
Advanceddisciplines:
disciplines:simulation,
simulation,enterprise material
material management, contract management,and
management, contract management,
enterprise and
integration,
integration, integrated automationprocesses,
integrated automation processes,and logistics functions.
and logistics functions.
interactive 3D and 4D modeling.
interactive 3D and 4D modeling.
Manteinance Construction
•• Operations •• Fluor's
Fluor'snetwork
networkofofconstruction
constructionresources
resourcesfacilitates
facilitatesthe
Operationsandandmaintenance
maintenance(O&M)
(O&M)services
servicesinclude
include the
plant maintenance, facility management, operations effective mobilization of advanced equipment and
plant maintenance, facility management, operations effective mobilization of advanced equipment and
support, skilled construction teams around the world. Fluor has
support,asset
assetperformance
performanceimprovement,
improvement,operations
operations skilled construction teams around the world. Fluor has
readiness, start-up and commissioning, and small extensive
extensiveexperience
experiencewith
withcountry
countryregulations
regulationsandand
readiness, start-up and commissioning, and small
capital managing culturally diverse workforces.
capitalproject
projectdesign
designand
andconstruction.
construction. managing culturally diverse workforces.
Project Management
•• Fluor
Fluorintegrates
integratesthetheactivities
activitiesofofthe
theengineering,
engineering,procurement,
procurement,and andconstruction
construction(EPC)
(EPC)functions
functionstotomeet
meetclient
clientexpectations.
expectations.
•• The company have managed large-scale capital projects involving billions of dollars of goods and services in challenging
The company have managed large-scale capital projects involving billions of dollars of goods and services in challenging
locations,
locations,integrating
integratingthe
theactivities
activitiesofofallallcontractors
contractorsand
andsubcontractors,
subcontractors,often
oftenfrom
fromdiverse
diversebackgrounds
backgroundsandandcultures.
cultures.
•• Fluor's
Fluor's fully integrated teams offer services and support in design, construction, procurement, project controls,safety,
fully integrated teams offer services and support in design, construction, procurement, project controls, safety,
quality, and, operations and maintenance.
quality, and, operations and maintenance.
116
Fluor – polysilicon case study
Polysilicon projects Jiangxi LDK PV Silicon Technology Co., Ltd. (LDK) Polysilicon Facility
Fluor acted as the EPCM contractor and managed the activities of multiple
Technology Know-How Providers (TKHPs) of the $1.2 billion LDK Polysilicon Facility
in Xinyu City, China.
To meet a global, growing demand for solar-grade silicon for the photovoltaic
industry, needed the services of a global EPCM leader. LDK contracted with Fluor
to design and build the world’s largest polysilicon plant next to its existing
multicrystalline solar wafer facility in Xinyu City.
Packages produced by the TKHPs include CVD reactors and converters, offgas
recovery units, and tricholorosilane (TCS) technology.
TKHPs are under contract directly to LDK; however, LDK contracted with Fluor to
integrate all the packages and complete detailed engineering to meet the 2009
start-up date.
Fluor worked with the Chinese design institutes to carry out design of utilities,
offsites, and infrastructure (U&I&O), and oversaw construction by a local
workforce to deliver this project to LDK on schedule.
The company used a multi-office execution approach to the LDK project using
Fluor engineering teams in Greenville, South Carolina; Manila, the Philippines; and
Shanghai, PRC.
117
CH2M Hill Lockwood Greene
CH2M HILL has thirteen business segments including Chemicals,

Electronics & Advanced Technology, Energy, Environmental
Government & Commercial Facilities, Life Sciences, Manufacturing,
Mining, Nuclear, Power, Sport & Event Management,
Transportation, and Wastewater & Water Resources.
Polysilicon technology is treated as a part of the Chemicals market.

CH2MHill has representation in more than 116 countries, involving
more than 24000 employees.
Chemicals division involves global professionals working with clients

to achieve their business objectives, whether they are expanding or
consolidating existing assets, using time-tested technologies, or
applying of first-of-a-kind chemical manufacturing processes in new
or existing facilities.
Services provided by the company include Applied Sciences

Laboratory, Architecture & Planning, Decontamination &
Decommissioning, Energy Management & Planning
Engineer-Procure-Construct (EPC) & Design-Build, Environmental
Management & Planning, Industrial Safety, Lean Enterprise
Solutions
O&M & Facilities Management, Procurement, Program &
Construction Management, Security & Emergency Management
Site/Infrastructure Planning, and Sustainable Solutions.
118
CH2M Hill Lockwood Greene – case study
Polysilicon projects Mitsubishi Polycrystalline Silicon Plant
To replicate their Yokkaichi, Japan Polycrystalline Silicon plant, Mitsubishi selected

a greenfield site near Mobile, Alabama that could exchange raw material and
recycle streams with an adjacent chemical plant. To successfully bring this 1,000-
ton-per-year plant on-line in the shortest possible time, CH2M HILL Lockwood
Greene was selected to provide conceptual design, Phase I and II environmental
site assessment, technology transfer from a basic engineering package prepared in
Japan, environmental permitting, process safety management, final process
design, final facility design, procurement of equipment, instruments, and lump
sum construction contracts, DCS software development, and full office and on-site
construction management services.
Lockwood Greene’s multi-office project execution utilized the technical resources of their Atlanta Office and the local
presence of their Mobile Office. The plant produces ultra pure (99.999999999% - 11Ns) polycrystalline silicon for subsequent
use in computer chip manufacturing.
The process includes HCl compression, fluidized bed chlorination, multistage cryogenic condensation, vapor purification by
absorption and stripping, multiple distillation steps, hydrogen gas purification, and electrolytic vapor phase chemical
deposition. Subsequent solid phase product processing, including grinding, and high purity water washing, drying, and
packaging are carried out in a clean room facility.
Process equipment, instruments, and piping required extreme cleaning measures, including solvent and acid cleaning prior to
erection. Process materials include metallic silicon, chlorine, hydrogen chloride, hydrogen, trichlorosilane, silicon
tetrachloride, nitric acid and hydrofluoric acid. Materials of construction include ceramic-lined steel, dual-laminated PVC/FRP,
ultra pure PVC piping, and jacketed piping.
119
CDI Engineering Solutions
CDI (NYSE: CDI) Process & Industrial division provides a full range
of engineering, outsourcing and staffing solutions to Fortune 500
companies in two distinct sectors: Process, which includes the
hydrocarbons and chemical processing industries, and Industrial,
which includes power and energy, telecommunications, and
heavy manufacturing.
CDI-Process & Industrial has offices located throughout North

America and, through strategic partnerships, also delivers
projects and high-value engineering solutions throughout Europe
and the Far East. Main headquarter is located in Philadelphia.
In addition to EPCM services, CDI also offers a broad array of

technical outsourcing, including engineering-focused IT services,
tailored to the needs of its customers.
In polysilicon industry, CDI provides coordination, evaluation, and

technical oversight of the basic engineering technology packages
produced for TCS plants, vent gas treatment systems and
polysilicon plant production area including chemical vapor
deposition reactors and converters. CDI will also provide the
balance of plant basic engineering services for the associated
utilities, offsites and infrastructure for the entire projects.
120
CDI Engineering Solutions – case study
Polysilicon projects Silfab Polysilicon Technology Integration Services

Headquartered in Padua, Italy, SILFAB S.p.A. is a newly established company with
the purpose of producing high quality solar-grade polysilicon in Italy, becoming a
supplier of high quality feedstock and a major player in this market segment.
SILFAB's project is already born as a fully integrated process: It starts from MGS
and delivers 9N-grade Polysilicon ingots, nuggets and photovoltaic (PV) wafers.
The company have completely closed-loop, fully integrated and self-dependent
production chain.
In 2008, to provide technology integration, basic engineering and detailed
engineering services for its polysilicon manufacturing project in Borgofranco
d'Ivrea, Italy, Silfab S.p.A. selected CDI Engineering Solutions.
Silfab's first phase of manufacturing expected to produce 2500 tons of solar grade polysilicon annually starting by the end of
2010, with plans to double the production capacity to 5000 tons. The product produced will be used to manufacture approx.
600 megawatts (MW) of solar capacity. Silfab's partners are leading companies who are strongly interested in the production
of solar grade polysilicon. Silfab's goal with this project is the production of high quality solar grade polysilicon for the
photovoltaic market.
CDI has been involved in the design of polysilicon projects utilizing similar processes for over a decade with many of its clients'
plants in operation today. As a leader in implementing TCS technology, CDI is providing technology integration, basic
engineering, Front-End Engineering Design (FEED) and Engineering Procurement Construction Management (EPCM) services
for polysilicon producing clients through a global project development organization dedicated to the polysilicon market and
headquartered in Houston,Texas.
121
Polysilicon market assessment
122
Spot versus contract transactions
Polysilicon spot pricing is subjected to continuous fluctuations.

Polysilicon’s producer engagement in spot contracts depends on its
business model
Transactions with Transactions on spot

contracts market
•In the past: 5-10 years •High flexibility of prices
contracts.
•Low guaranty of product
•Nowadays: 1-2 years contracts. quality and stability of supply
•Restriction to one supply and •Prices differ from contract
price transactions basing on the
product quality, timeline of
•Security of the commodity
supply and size of the
supply and demand
shipment
•Basing on company’s business
•Uncertainty of spot
model ratio of contracts
transactions influences
transaction can vary.
companies to secure their
•Usually, prepayment is supply via contracts.
included in contracts
Well established polysilicon players are trying to secure their sale via contract transactions.
Spot transactions are occasional (~1/3 of whole sale) and limited to polysilicon oversupply or new players without good branding.
123
Metallurgical silicon market
Metallurgical silicon, i.e.

~ 50% silicon with a purity of at least
98% is used mostly in the
presented sectors.
MG Si is produced in electric
arc furnaces, and silicon plants
are usually located in areas,
~ 40% where there is ample supply
of quartz and coal. Most
producers choose to be
located in places that are close
to cheap, hydroelectric power
as well as a quartz supply. It is
~ 10% estimated that around 2.5 to 3
metric tons of quartz are
needed to make one ton of
silicon metal
Shares of the chemical and aluminum industries in mg – Si market have been influenced by crisis.
Both of these sectors are comparable in demand and characterize by continuous moderate growth.
124
Metallurgical silicon production
Metallurgical silicon, i.e. Global demand for metallurgical silicon
silicon with a purity at 3000
least 98%, is a popular

raw material in: 2500
•Aluminum industry 2000
•Chemical industry
mt 1500
•Solar industry
After the economic downturn, the
1000
•Semiconductor industry is expacting continous
growth of demand for mg-Si.
industry
500
Due to the economic

crisis that affected main 0
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
receivers of aluminum. year
Consumption and prices
of this commodity have The Aluminum industry consumes nearly 45% of the global
dropped in 2008. production of this commodity. Together with the chemical
industry they can utilize approximately 90% of its volume.
Source: Timminco, Frost & Sullivan 125
Metallurgical silicon spot prices
The production of
400 European spot prices
metallurgical silicon is In 2007 - 2008,
US import spot prices
market has
driven mostly by experienced
350
Chinese and European huge price
increase
producers. 300
cents per kg
Despite of the
250
economic downturn
affecting main
200
consumers of mg-Si
Due to the economic downturn,
the market for this 150 the price has fallen at the leverls
commodity is of 230 - 270 cents per kg, and now
market is regaining its power.
rebounding. Thus, the 100
prices for the mg-Si 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
are slowly climbing. year
The continuous trend of growing prices would not effect in reaching levels from 2008 in
near future.
126
Polysilicon market assessment
- Solar grade silicon
127
Demand and Supply for Polysilicon
Both, semiconductor and solar applications are expected to have substantial inflows of
investment to finance corporations and projects.
Corporate finance: investment principally alludes to government grants, venture capital, private
equity, corporate debt and public equity. Depending on the company’s size and stage of
development, these various types of investment enable corporate operations and expansion.
Project finance: investment relates debt, tax equity and private equity. Project finance is
necessary for the development, construction and operation of polysilicon installations.
Demand and Supply for Polysilicon
300 Supply Semi-G
250
Thousand Metric Tons
Demand Semi-G
200
Supply Solar-G
150
Demand Solar-G
100
50
0
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Year
128
Prices for Polysilicon
2009 economic downturn has significantly affected the growth of the polysilicon markets all over the world generating the
drop of the market prices. Solar grade PSi will fell down gradually reaching a pricing levels near 30 $ per kg.
• Current government policies and new 500

investments tending to promote clean Solar Grade Silicon Spot Prices
technologies in many countries drive the prices 450
of polysilicon solar grade.
• Emerging technologies related to 400
microelectronics are in constant development 350
requiring ultra high purity polysilicon, produce a
similar effect in polysilicon electronic grade. 300
[$ per kg]
•PV market is witnessing increasing polysilicon
quality expectations with regard to material 250
performance , i.e. purity levels. In effect, the 200 Solar Grade Silicon Spot
differences between semiconductor grade and Prices
silicon grade silicon could be lower than they 150
are now.
100
• However, PV market will be still price oriented
with regard to the silicon and would utilize less 50
pure and cheaper material comparing to the
semiconductor market. 0
•The raising quality expectations for solar grade 2004 2006 2008 2010 2012 2014 2016 2018
would result in establishing new purity
year
standards level for this market.
Increasing expectations of some of the solar cells producers would not be met in future with 9N purity levels
129
Polysilicon Solar Market: Drivers
Government policies
promote the
increment in the PV
installed capacity
Current financial and

credits
announcement for
leader companies to
impulse the industry
growth Increasing demand for
Improvements in the electricity for especially
prior art Alliances between leader
for domestic and
manufacturing companies incrementing
personal applications
process decreasing their production capacity
costs and energy and fusioning technology
Source: Frost & Sullivan.
130
Polysilicon Solar Market: Restrains
High energy cost Brand orientation of

used for polysilicon polysilicon due to the
Competition from non Production and low quality product from
silicon PV systems processing. new entrants.
Antidumping taxes
and restraining
policy of few
countries.
2009 economic
downturn has
affected the
growth of the
polysilicon
markets
131
Polysilicon Solar Market: Drivers and Restrains
Drivers Restraints
2012 2014 2016 2012 2014 2016
2009 economic
Government policies promote downturn has affected
the increment in the PV installed the growth of the
capacity polysilicon markets
Antidumping taxes and

Current financial and credits
restraining policy of few
announcement for leader
countries.
companies to impulse the
industry growth
Brand (quality) orientation of

Improvements in the prior art
polysilicon users due to the
manufacturing process
low quality product from
decreasing costs and energy
new entrants.
Alliances between leader High energy cost

companies incrementing used for polysilicon
their production capacity Production and
and fusioning technology processing.
Increasing demand for electricity Competition from

for especially for domestic non silicon PV systems
and personal applications
132
Semiconductor-Grade Polysilicon: Supply and Demand
• The silicon purity of Semi-G is 99.9999999%-99.999999999% (9N to 11N)

• The market for PSi is shared between semiconductor and solar. In 2000, only 10% of PSi was used for solar
cells, rising to over 75% in 2009. This trend will continue in the next decade.
• The demand of Semi-G PSi is driven by semiconductor integrated circuit companies, with a steady grow rate
estimated at 7% from year 2009. In Year 2015 the demand is likely to reach ~ 40000 ton/year.
• The major suppliers of Semi-G Psi are Wacker (Germany), Hemlock (USA), Tokuyama (Japan), Mitsubishi
(Japan&USA), Asimi (USA), MEMC(USA). The first three took 60% of the market share in Year 2009.
• Due to the technology entry barrier and limited profit margin, no major player is likely to enter this market
sector. The supply of Semi-G Psi is estimated to grow at a rate of 3-4%. In Year 2013, the supply is like to
reach above 29000 ton/year.
133
Semiconductor-Grade Polysilicon: Price
• It is established that the price of Semi-G PSi is slightly higher than Solar-G PSi.
• Following a collapse in demand for solar electricity at the same time as new polysilicon has come
online, the spot price for Semi-G PSi has collapsed from 500USD/kg in August 2008 to the current
quote for June 2010 80-100USD/kg.
• We estimated the price of Semi-G Polysilicon to be stabilized at 50USD/kg in Year 2015.
134
Polysilicon Semiconductor Market: Drivers
Increasing
requirements of
semiconductor
industry due to the.
scaling down of
integrated circuit
Technology
advancement
Established and in producing
Long-term stable high purity
dominant status of
contracts between polysilicon in
silicon applications
metallurgical silicon an affordable
in semiconductor
supplier and way
industry versus new
electronics
materials
manufacturers
135
Polysilicon Semiconductor Market: Restrains
Competing
technologies
(germanium, Entry barrier is
nanomaterials, relatively high due to
Maturity level of polymers) pose technology
the substitution monopoly, lack of
semiconductor threat for silicon experience
Lower cost of solar
silicon industry grade production
and huge demand
from PV market
supporting
production of the
SOG instead of SEG
High investment cost

in the preliminary
stage of building
plants
136
Polysilicon Semiconductor Market: Analysis of Drivers and
Restrains
Drivers Restraints
2012 2014 2016 2012 2014 2016
Increasing requirements of
semiconductor industry Maturity level of the
due to the. scaling down of semiconductor silicon
integrated circuit industry
Technology
Advancement in Competing technologies
producing high purity (germanium, nanomaterials,
polysilicon in an polymers) - substitution
affordable way threat for silicon
Long-term contract Relatively high entry

between metallurgical barrier due to technology
silicon supplier and monopoly, lack of
electronics manufacturers experience.
Established and dominant High investment cost in the

status of silicon preliminary stage of building
applications in plants
semiconductor industry
versus new materials Lower cost of solar grade
production and huge
demand from PV market
supporting production of the
SOG instead of SEG
137
Competitive landscape -
New polysilicon capacities
138
New Polysilicon capacities globally
Name Region Capacity [t/y] year type

Bhaskar Silicon Asia 2500 2011 SOG
DunAn Photovoltaic Asia 3000 2011 SOG
Global PV specialists NA 1000 2011 SOG
Huaxuan PV technolo Asia 1000 2011 SOG
Iacharya Silicon Asia 250 2011 SOG
LG Chem Asia 5000 2011 SOG/SEG
Wacker Schott Europe 1000 2012 SOG
Qatar Solar Technologies Asia 5000 2012 SOG
Peak Sun Silicon NA 5000 2012 SEG
Peak Sun Silicon NA 5000 2013 SEG
Hemlock Semiconductors NA 10000 2012 SOG
Globe Specialty Metals (Solsil) NA 4000 2011 SOG
Wacker Chemie Europe 10000 2011 SOG/SEG
Euro Multivision Asia 500 2011 SOG
OCI Asia 5000 2011 SOG
GCL Silicon Asia 30000 2011 SOG
Fushun Koshuha Foundry Co. Asia 10000 2011 SOG
Mitsubishi Asia - - SEG
Hoku Corporation Asia 4000 2011 SOG
139
Analysis of emerging new polysilicon capacities
61250
•Boom in investments in
2011
polysilicon industry has 10000
2012
been weakened due to 1000

2013
the economic downturn.

Various entities had to
postpone or abandon 5000
15000
their development plans
due to the difficulties with 5000 5000
financial liquidity.
•However, some facilities
were built and started
production of polysilicon
despite of the difficult •Expansion of solar polysilicon production is the most popular
situations. trend. Continuously increasing demand for this commodity from PV
•Demand for polysilicon is area has attracted some companies to enter this business.
still significant and various •Well established polysilicon players continue expansion plans
players continue targeting not only solar but also semiconductor markets.
production expansion •Some of these companies have already signed contracts for
polysilicon supply up to 2018.
activities.
140
Competitive landscape -
M&A tendencies
141
Merger & Acquisitions
DE
DEhashasestablished
establishedstrategic
strategicalliance
alliancewith
withPolycrystalline
PolycrystallineSiilcon
SiilconTechnologies.
Technologies.As Asaaresult,
result,the
the
DE is now offering PST’s advanced hydrochlorination technology, as well as chlorosilane
DE is now offering PST’s advanced hydrochlorination technology, as well as chlorosilane and and
Dynamic
DynamicEngineering silane
Engineering silanetechnology.
technology.Prior
Priortotothis
thisagreement
agreementthe
theDEDEwas
wasoffering
offeringchlorination
chlorinationtechnology.
technology.Now,Now,
the inforporation of PST technology would allow for the optimization of state
the inforporation of PST technology would allow for the optimization of state of the artof the art
poysilicon
poysiliconplant
plantdesign
designtotoincrease
increaseeconomic
economicside
sideofofthe
theprocess.
process.
QST
QSTplans
planstotodevelop
developpolysilicon
polysiliconplant
plantatatRas
RasLaffan
LaffanIndustrial
IndustrialCity
CityininQatar.
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plantwill
willbe
be
producing polysilicon for solar panels. On 1 March 2010 the joint venture agreement
producing polysilicon for solar panels. On 1 March 2010 the joint venture agreement was was
signed
signedbetween
betweenQatar
QatarFundation,
Fundation,Qatar
QatarDevelopment
DevelopmentBank Bankand
andSolar
SolarWorld
World(german
(germanPVPV
Qatar
QatarSolar
Solar player). The participants will cover 70 %, 1 % and 29% shares of new enterprise, respectively.
player). The participants will cover 70 %, 1 % and 29% shares of new enterprise, respectively.
Technologies
Technologies InIn2010
2010the
theconstruction
constructionisisexpected
expectedtotostart,
start,ininQ32012
Q32012production
productionisisexpected
expectedtotostart.
start.QST
QST
has signed agreement with Centrotherm photovoltaics AG for the supply
has signed agreement with Centrotherm photovoltaics AG for the supply of technology,of technology,
equipment
equipmentand andengineergin
engineerginandandproject
projectservices.
services.
LTST
LTSThas
hasstarted
startedupupitsitspolysilicon
polysiliconproduction
productionininLeshan,
Leshan,Sichuan
Sichuanprovince
provinceininChina.
China.Their
Their
polysilicon will be used for production of solar cells and modules and wafers
polysilicon will be used for production of solar cells and modules and wafers for the for the
Ledian electronic
electronicindustry
industryasaswell.
well.InInthis
thisregard,
regard,company
companyhas hascooperated
cooperatedwith
withPoly
PolyPlant
PlantProject
LedianTianwei
TianweiSilicon
Silicon Project
Technology Inc.
Inc. by purchasing its proces technology and equipment. The equipment was comissionedinin
by purchasing its proces technology and equipment. The equipment was comissioned
Technology
August
August2009
2009and
andthetheplant
plantstarted
startedininproduction
productionininSeptember.
September.The
Thecompany
companyisisnownowcapable
capable
ofofproducing solar and semiconductor polysilicon at a rate
producing solar and semiconductor polysilicon at a rate 1500 MT. 1500 MT.
142
GT
GTSolar
Solarhas
hasrecently
recentlybegun
beguninstalltion
installtionofoftis
tissystem
systemfor
forcrystalline
crystallinesilicon
siliconsystem
systemforforthethe
GT wafer
waferproduction
productionline
lineatatGCL
GCLSolar
Solarfacility.
facility.Current
Currentactivity
activityisisaapart
partofofGCL
GCLpurchase
purchase
GTSolar
Solar agreement
agreement and both companies plant to cooperate further on this topic. Thefacility
and both companies plant to cooperate further on this topic. The facilityisis
located
locatedininChina
Chinaand
andGCL
GCLhas
hasput
putstringent
stringenttimetimerequirements
requirementsfor forfinishing
finishingthis
thisfacility.
facility.
GT
GTSolar
Solarhas
hasannounced
announcedthat
thatcompany
companysigned
signedagreement
agreementfor forcrystalline
crystallineingot
ingotgrwoth
grwothfurnace.
furnace.
The
The recipient of the system is Chinese Yingli Green Energy Holding. System will be installedinin
recipient of the system is Chinese Yingli Green Energy Holding. System will be installed
company’s
company’snew newHainan’s
Hainan’sproduction
productionfacility.
facility.The
Theproduced
producedsilicon
siliconwill
willtarget
targetsolar
solarindustry
industry
GT
GTSolar
Solar needs.
needs. Yingli Green Energy covers the entire photovoltaic value chain, from the productionfofo
Yingli Green Energy covers the entire photovoltaic value chain, from the production
polysilicon
polysiliconthrough
throughingot
ingotcasting
castingand
andwafering
waferingtotosolar
solarcell
cellprodcution
prodcutionand andmodule
moduleassembly.
assembly.
Produced moduels are distributed in Europe, Asia
Produced moduels are distributed in Europe, Asia and USA.and USA.
Wacker
WackerChemie
Chemiehashassecured
securedits itsproduction
productionofofpolysilicon
polysiliconbybyacquisition
acquisitionofofthe
thesilicon
siliconmetal
metal
production
production site in Holla, Norway from Fesil Group. Due to the transaction Wacker willbe
site in Holla, Norway from Fesil Group. Due to the transaction Wacker will be
Wacker more independent or raw material price flucuations and increase its supply security during
WackerChemie
Chemie more independent or raw material price flucuations and increase its supply security during
peak
peakdemand
demandperiods.
periods.Holla
HollaMetall’s
Metall’sproduction
productioncapacity
capacityisisaround
around50000
50000metric
metrictons
tonsofof
silicon
silicon, ,whic
whichis
hisabout
about1/3
1/3ofofWacker’s
Wacker’scurrent
currentannual
annualneed.
need.
143
Jiangsu JZPT
JZPThas
hasacquire
acquirethe
theGCL-Poly
GCL-PolyEnergy
EnergyHolding
Holdingininaareverse
reversemerger
mergertransaction.
transaction.The
Thecompany
company
JiangsuZhongneng
Zhongneng engages
Polysilicon
Polysilicon engagesininthe
theenergy
energysector
sectorand
andowns
owns14 14coal
coalfulelled
fulelledcogeneration
cogenerationplants,
plants,22gas
gasfuelled
fuelled
Technology cogeneration
cogeneration plants, 2 biomass cogeneration plants and 1 solid waste incineration plant.InIn
plants, 2 biomass cogeneration plants and 1 solid waste incineration plant.
Technology total
totalthe
theinstalled
installedcapacity
capacityofofplants
plantsisis1050
1050MW.
MW.
Hoku
HokuMaterials
Materialsinistiaged
inistiagedpilot
pilotproduction
productionofofpolysilicon
polysiliconatatits
itsmanufacturing
manufacturingfacility
facilityininIdaho.
Idaho.
Hoku
HokuMaterials
Materials They have commenced initial operational testing of its Siemens based polyslicon production
They have commenced initial operational testing of its Siemens based polyslicon production
line
lineusing
usingtrichlorosilane
trichlorosilanepurchased
purchasedfrom
fromthird
thirdparties.
parties.
Euro
EuroMultivision
MultivisionLtd
Ltdisisaaindian
indiansecond
secondlargest
largestproducer
producerofofCDRs
CDRsand
andDVDRs.
DVDRs.Recently,
Recently,
company
company has realized plans to produce polysilicon. In this regard, company hasstarted
has realized plans to produce polysilicon. In this regard, company has started
Euro
EuroMultivision
MultivisionLtd
Ltd cooperation with SRI as technology provider. Initially, company planned to start the
cooperation with SRI as technology provider. Initially, company planned to start the
photovoltaic
photovoltaicproduction
productionfacility,
facility,but
butchanged
changedtheir
theirminds
mindsandanddecided
decidedtotoproduce
producesolar
solargrade
grade
silicon. The production may start at the end of
silicon. The production may start at the end of 2011. 2011.
144
End market analysis -
Solar cells
145
Photovoltaic market analysis – opportunities for silicon
Solar cells market will be still attractive area for silicon producers
There is competition between silicon solar cells and other PV solutions
2nd
nd, 3rd
rd generation solar cells
Silicon based technologies
(without silicon)
• Silicon was the first material used for solar cell • Increasing price of the silicon in the past
purposes. Its well understood and developed triggered development of competing
processing technology stimulated development technologies like 2nd
nd and 3rd
rd generation solar
of this area. cells, which do not use silicon or use it in non

• Attractiveness of the silicon PV systems resulted crystalline form.
from good price to performance ratio. • Competing solutions like CdTe, CIGS or
• Silicon solar cells are one of the most efficient PV polymeric solar cells prevail over silicon with
solutions with well developed value chain. its lower price, easier fabrication and
potential flexibility.
Solar market is characterized by trade off between silicon and non silicon solar cells.
146
Photovoltaic market analysis – opportunities for silicon II
Decreasing prices of silicon changed the market and silicon solutions are again perceived as highly attractive.
Global programs supporting development of PV systems should significantly stimulate
silicon market.
2nd
nd, 3rd
rd generation solar cells
Silicon based technologies (without silicon)
•• Due
Duetotothe
theprice
pricedecrease
decreaseand andrecent
recent •• 22ndndand rd
and33rdgeneration
generationsolarsolarcells
cellshave
havelost
losttheir
their
technological
technological developments siliconsolar
developments silicon solarcells
cellsare
are good position against silicon solar cells
good position against silicon solar cells mostlymostly
now in good position to target
now in good position to target various various based
basedon onthe
thelower
lowerrawrawmaterial
materialprice.
price.
applications
applicationsareas.
areas. •• Cost
Cost of such elements like indium orgallium
of such elements like indium or galliumstill
still
•• The
The most significantbenefits
most significant benefitswithwiththis
thistechnology
technology influence price of some of the new generation
influence price of some of the new generation
are
are observed in case of limited area solarsystems
observed in case of limited area solar systems PVPVsystems
systemsandandmake
makethem
themless
lessattractive
attractive
(like on the roof of house) or in concentrated
(like on the roof of house) or in concentrated comparing
comparingtotosilicon
siliconPV.
PV.
photovoltaic
photovoltaicsolutions,
solutions,where
whereapartapartfrom
from •• Low
Low efficiency and durabilityofofsome
efficiency and durability someofofthethenew
new
traditional
traditional solar module there is a systemfor
solar module there is a system forlight
light generation PV systems require their
generation PV systems require their further further
concentration and orientation toward
concentration and orientation toward sunlight. sunlight. development
developmentininorder ordertotocompete
competewithwithsilicon
silicon
•• Perpsective
Perpsectiveofofsilicon
siliconininsolar
solarcells
cellsare
arestable
stableand
and solutions.
solutions.
should
shouldnotnotchange
changedramatically
dramaticallyduringduringnext
nextfew
few •• InInless
lessdemanding
demandingapplications,
applications,like
likeportable
portablePVPV
years.
years. systems, large PV farms, new generation
systems, large PV farms, new generation PV PV
systems
systemscouldcouldbebemore
moreadvantegous
advantegousthan than
silicon.
silicon.
147
End market analysis -
Semiconductor market
148
Semiconductor market analysis – opportunities for silicon
Semiconductor market would be still and reliable client of semiconductor grade silicon
Silicon has dominated the semiconductor market and competing solutions are less popular.
Silicon based technologies Non silicon technologies
• Semiconductor silicon technology is in mature • Technical limitations of silicon like conductivity, low
phase and take advantage of the well temperature of usage, week flexibility have
understood and developed technical aspects. triggered researches on other materials like
• Silicon allows for cheap, large scale and reliable germanium, nitrides or polymeric systems such as
IC systems, which are not accessible by other pedot, pss, etc…
competing techniques. • Investigation of nanomaterials in semiconductor

systems resulted in new technical solutions like
• Limitations of silicon have triggered development
FET, or conductive systems. However, these
of competing technologies, but their ready to use
innovations require at least 5 years of development
state will take place after 2020.
before they would start to compete with silicon IC.
Well understood and developed silicon technology will still dominate in semiconductor market in near future.
149
Conclusions
150
Conclusions
•• Production
Productionofofsilicon
siliconcould
couldlead
leadtotomostly
mostly22typestypesofofits
itsgrades:
grades:semiconductor
semiconductorand andsolar.
solar.Upgraded
Upgradedmetallurgical
metallurgicalsilicon
siliconwaswas
deemed
deemedasasinteresting
interestingraw rawmaterial
materialonly onlyduring
duringthe thehigh
highsilicon
siliconprices
pricesperiod.
period.
•• Production
Productionofofsemiconductor
semiconductorgrade gradesilicon
siliconisisdone
doneby bywell
wellestablished
establishedmarketmarketplayers,
players,who whocan canassure
assurethe thequality
qualityandandthe
the
stability of silicon supply. These factors are important for the clients from semiconductor
stability of silicon supply. These factors are important for the clients from semiconductor (mostly) and solar market. (mostly) and solar market.
•• Higher
Higherprice
priceforforsemiconductor
semiconductorsiliconsiliconthanthanforforsolar
solargrade
graderesults
resultsfrom
fromhigher
higherpurity
purityrequirements
requirementsand andmaterial
materialmono-
mono-
crystallinity. This material is mostly produced by Siemens
crystallinity. This material is mostly produced by Siemens method. method.
•• Limited
Limitedaccess
accesstotowellwelldeveloped
developedsemiconductor
semiconductorgrade gradetechnologies
technologiesisisstillstillaabarrier
barrierforformarket
marketentry
entryasaswellwellasasthe
thehigh
high
capital costs for new semiconductor grade silicon enterprise, which requires financial
capital costs for new semiconductor grade silicon enterprise, which requires financial support for new player. support for new player.
•• Silicon
Siliconsemiconductor
semiconductormarket marketisisininmature
maturephase.
phase.
•• Scalability
Scalability of silicon production enables easychoice
of silicon production enables easy choiceofoffacility
facilitysize
sizeand
andperformance.
performance.
•• Solar
Solar market is expected to develop vitally under incentive governmentalprograms
market is expected to develop vitally under incentive governmental programsacrossacrossthetheworld
worldand andthetheincreasing
increasing
demand
demandfor forelectricity.
electricity.
•• Developments
Developmentsininthe thePVPVR&D
R&Dareaareawill
willeffect
effectininsilicon
siliconsolar
solarcells
cellsperformance
performanceincrease.
increase.Competition
Competitionfrom fromother
othersolar
solarcells
cells
technologies have weakened due to the beneficial cost to price comparison of silicon devices
technologies have weakened due to the beneficial cost to price comparison of silicon devices after the economic downturn after the economic downturn
silicon
siliconprice
pricedecrease.
decrease.Assuming
Assumingsilicon
siliconsolar
solargrade
gradeprices
pricesatatthethelevel
levelofof3030$$per
perkgkgthis
thistrend
trendwillwillsupport
supportthe thePV PVmarket
market
growth.
growth.
•• Production
Productionofofsolar solargrade
gradesilicon
siliconisisless
lessdemanding
demandingthan thansemiconductor
semiconductorgrade. grade.Various
Varioustechnologies
technologiesare arecapable
capablefor forbeing
being
used in this regard. The know how requirements in case of solar grade silicon are less stringent
used in this regard. The know how requirements in case of solar grade silicon are less stringent than for semiconductor than for semiconductor
silicon
siliconproduction.
production.
•• Energy
Energy cost,which
cost, whichisistremendous
tremendousfor forsilicon
siliconproduction,
production,forces
forcesmarket
marketplayers
playerstotolocate
locatetheir
theirfacility
facilityininthe
theareas
areaswith
with
relatively low electricity cost ( for instance in US, Iceland,
relatively low electricity cost ( for instance in US, Iceland, etc…). etc…).
•• Purity
Purityrequirements
requirementsfor forsolar
solargrade
gradesilicon
siliconisisincreasing
increasingand andsomesomesolar
solarproducers
producersare arenot
notsatisfied
satisfiedwith
with9N 9Npurity
puritylevel.
level.InIn
effect,
effect,differences
differencesbetween
betweensemiconductor
semiconductorgrade gradeandandsolar
solargrade
gradesilicon
siliconwill
willbe
bedecreasing
decreasingdepending
dependingon onthe
thesolar
solarmarket
market
requirements.
requirements.
151
Conclusions II
•• The
TheSiemens
Siemensmethod
methodisisone
oneofofthethebest
bestunderstood
understoodand andutilized
utilizedtechniques
techniquesfor forhigh
highpurity
puritysilicon
siliconproduction.
production.
•• The
The CVD FBR methods are still at development phase and require adjustment with regard to qualityand
CVD FBR methods are still at development phase and require adjustment with regard to quality andsynthesis
synthesisissues.
issues.
•• So
So far the CVD FBR have found applicability in less demanding solar grade silicon production. However, some entitieshave
far the CVD FBR have found applicability in less demanding solar grade silicon production. However, some entities have
problems with environmental
problems with environmental issues.issues.
•• Other
Othertechniques
techniquescome
comewith
withcomparable
comparableororhigher
highercosts
costsand
andare
areless
lessdeveloped
developedininorder
ordertotomeet
meetclients
clientsrequirements.
requirements.
•• Despite
Despite of the production and purification, form of the silicon – ingot, chunks, granular, impacts processingofofthis
of the production and purification, form of the silicon – ingot, chunks, granular, impacts processing thismaterial
material
and its cost. The FBR CVD methods provides easy to use granular
and its cost. The FBR CVD methods provides easy to use granular silicon. silicon.
•• Pricing
Pricinglevels
levelsand
andsilicon
siliconquality
qualityrequirements
requirementswould
wouldfacilitate
facilitategrowth
growthofofthe
thepolysilicon
polysiliconproduction
productionindustry
industryfor
forboth
bothsolar
solar
and semiconductor areas.
and semiconductor areas.
152

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“Assessment of Polysilicon Global Market

and it’s Fabrication Technology Landscape”

Final Report for Rusnano

July 26, 2010

Major production steps for a crystalline silicon include:

Silicon is usually used at the

Demand for silicon for aluminum

Present Capacity (MT

North and Latin America

Plans to retool an existing MG-Si plant

Rima Industrial S/A Brazil 60,000 NA

Minas Ligas Brazil 22,000 NA

Present Capacity (MT

100,000 (MG-Si) Plant 1 has a capacity of 5000 MT. Capacity

RW Silicium GmbH Germany 35,000

Total production was expected to reach

2000 (solar grade

Plant Location: Rodovia PA 263 KM 3,5, Breu Branco – PA – Brazil

Production capacity: 42,000 – 44,000 MT per year

Silicon source: Quartzite mine in Pará, Brazil

Special features: Introduced in Sept 2006 the PV industry's first commercially

Special features: Leading Brazilian producer of silicon-based alloy

Location: Belo Horizonte, Brazil

Production Capacity: 60,000 metric tons

Plants: Capitao Eneas, Bocaiuva & Varzea de Palma

Production capacity: 46,000 MT per year

Silicon sources: Mine in Pirapora, Minas Gerais, Brazil

% Fe (max.) 0.50 0.40 0.50 0.20

% Al (max.) 0.50 0.25 0.30 0.02

% Ca (max.) 0.40 0.03 0.03 0.03

Production capacity: 223,000 tons

Plants belonging to Ferroatlantica:

Plants belonging to Ferropem:

Special features: The company is dedicated to converting metallurgical grade silicon

Special features: World’s largest producer of aluminum and alumina

Special features: 90 % of FESIL's products is meant for the EU market

Location: Holla Metal Kyrksæterøra, Norway

Production Capacity: 48,000 tons

Plants: Holla Metall plant, Kyrksæterøra, Norway

Special features: Germany’s only producer of silicon metal

Si-Metall 3303 99,00 0,30 0,30 0,03

Si-Metall 2202 99,50 0,20 0,20 0,02

Markets: aluminium alloys, chemical, PV and semiconductor industries

Growth of PV solution utilizing processes for material

Note: Size of the sphere identifies the impact on the market

The price of silicon metal has increased due to increasing demand.

Metallurgical silicon upgraded using metallurgical process is viewed as

0 50 100 150 200 250 300 350

• Semi M16-1103 • Specification for P-Si for electronic grade

• Semi M24-0307 • Specification for polished mono-c-Si

Concentration Concentration Concentration Concentration

aluminum 1000-4350 manganese 50-120

Si + 3HCl -> SiHCl3 + H2

HCl is produced via a a H2 +Cl2 reaction . The oversupply of hydrogen is used to

PROCESS OF MANUFACTURE OF POLYSILICON from TCS has two steps

Recovery of gases, purification,

Trichlorosilane liquid is vaporized. Hydrogen gas is

SiHCl3 + H2 -> Si + 3HCl

PURIFICATION AND RECYCLE

3SiCl4 + Si + 2H2 -> 4Si HCl3

• The raw material for FBR is silane, which can be

4SiHCl3 SiH4 + 3 SiCl4

• The FBR method utilizes the silane (SiH4) or TCS as a

Frost&Sullivan Polysilicon 2010

Frost&Sullivan Polysilicon 2010