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A two inch-diameter stainless steel reactor was designed to operate at pressure up to 500 psig and at temperature up to 600 C in order to study the hydrochlorination of silicon tetrachloride and metallurgical grade (m.g.) silicon metal to trichlorosilane. The hydrochlorination apparatus is described and operation safety and pollution control are discussed.
A two inch diameter stainless steel reactor was designed and built to operate at pressures up to 500 psig for the experimental studies on the hydrochlorination of SiCl4 and metallurgical grade (m.g.) silicon metal to SiHCl3. In order to clearly see the effect of pressure, the experiments were carried out at low reactor pressures of 73 psig and 150 psig, respectively. A large pressure effect on the hydrochlorination reaction was observed between the results of the low pressure experiments and the results of the high pressure experiments. In general, higher pressure produces a higher conversion of SiHCl3, but at a lower reaction rate. The effect of temperature on the reaction rate was studied at 73 psig. Higher reaction temperature gave a higher conversion and a higher reaction rate. Samples of the materials used to construct the hydrochlorination reactor were prepared for corrosion tests.
Equipment developed for the manufacture of over 100 kg of silicon ingot from one crucible by rechanging from another crucible is described. Attempts were made to eliminate the cost of raising the furnace temperature to 250 C above the melting point of silicon by using an RF coil to melt polycrystalline silicon rod as a means of rechanging the crucible. Microprocessor control of the straight growth process was developed and domonstrated for both 4 inch and 6 inch diameter. Both meltdown and melt stabilization processes were achieved using operator prompting through the microprocessor. The use of the RF work coil in poly rod melting as a heat sink in the accelerated growth process was unsuccessful. The total design concept for fabrication and interfacing of the total cold crucible system was completed.
The engineering design, fabrication, assembly, operation, economic analysis, and process support R and D for an Experimental Process System Development Unit (EPSDU) are reported. About 95% of purchased equipment is received and will be reshipped to the West Coast location. The Data Collection System is completed. In the area of melting/consolidation, to the system using silicon powder transfer, melting and shotting on a pseudocontinuous basis is demonstrated. It is proposed to continue the very promising fluid bed work.
Potential small wind energy conversion (SWECS) design problems were identified to improve product quality and reliability. Mass produced components such as gearboxes, generators, bearings, etc., are generally reliable due to their widespread uniform use in other industries. The likelihood of failure increases, though, in the interfacing of these components and in SWECS components designed for a specific system use. Problems relating to the structural integrity of such components are discussed and analyzed with techniques currently used in quality assurance programs in other manufacturing industries.
Some 20 x 20 aluminum panels were studied in a frequency range from 20 Hz to 5000 Hz. The noise sources used were a swept sine wave generator and a random noise generator. The effect of noise source was found to be negligible. Increasing the pressure differential across the panel gave better noise reduction below the fundamental resonance frequency due to an increase in stiffness. The largest increase occurred in the first 1 psi pressure differential. The curved, stiffened panel exhibited similar behavior, but with a lower increase of low frequency noise reduction. Depressurization on these panels resulted in decreased noise reduction at higher frequencies. The effect of damping tapes on the overall noise reduction values of the test specimens was small away from the resonance frequency. In the mass-law region, a slight and proportional improvement in noise reduction was observed by adding damping material. Adding sound absorbtion material to a panel with damping material beneficially increased noise reduction at high frequencies.
An improved method, based on one strip approximation of the method of integral relations which was reported originally by Belov, Ginzburg and Shub (1973), is presented for the calculation of flow parameters in the impingement region of a supersonic, underexpanded jet striking a normal surface located within the first cell. The results are presented for two impingement conditions and found to be in good agreement with the experimental data.
Progress and continuing plans for the joint NASA/DoE program at the JPL to develop the technologies and industrial processes necessary for mass production of low-cost solar arrays (LSA) which produce electricity from solar cells at a cost of less than $0.70/W are reviewed. Attention is given to plans for a demonstration Si refinement plant capable of yielding 1000 MT/yr, and to a CVD process with chlorosilane, which will yield material at a cost of $21/kg. Ingot and shaped-sheet technologies, using either Czochralski growth and film fed growth methods have yielded AM1 15% efficient cells in an automated process. Encapsulation procedures have been lowered to $14/sq m, and robotics have permitted assembled cell production at a rate of 10 sec/cell. Standards are being defined for module safety features. It is noted that construction of a pilot Si purification plant is essential to achieving the 1986 $0.70/W cost goals.
The electrical power output from a photovoltaic module is strongly influenced by the thermal and optical characteristics of the module encapsulation system. Described are the methodology and computer model for performing fast and accurate thermal and optical evaluations of different encapsulation systems. The computer model is used to evaluate cell temperature, solar energy transmittance through the encapsulation system, and electric power output for operation in a terrestrial environment. Extensive results are presented for both superstrate-module and substrate-module design schemes which include different types of silicon cell materials, pottants, and antireflection coatings.
The nominal operating cell temperature (NOCT) of solar photovoltaic (PV) modules is an important characteristic. Typically, the power output of a PV module decreases 0.5% per deg C rise in cell temperature. Several tests were run with artificial sun and wind to study the parametric dependencies of cell temperature on wind speed and direction and ambient temperature. It was found that the cell temperature is extremely sensitive to wind speed, moderately so to wind direction and rather insensitive to ambient temperature. Several suggestions are made to obtain data more typical of field conditions.
Silane decomposition in a fluidized-bed reactor (FBR) process development unit (PDU) to make semiconductor-grade Si is reviewed. The PDU was modified by installation of a new heating system to provide the required temperature profile and better control, and testing was resumed. A process for making trichlorosilane by the hydrochlorination of metallurgical-grade Si and silicon tetrachloride is reported. Fabrication and installation of the test system employing a new 2-in.-dia reactor was completed. A process that converts trichlorosilane to dichlorosilane (DCS), which is reduced by hydrogen to make Si by a chemical vapor deposition step in a Siemens-type reactor is described. Testing of the DCS PDU integraled with Si deposition reactors continued. Experiments in a 2-in.-dia reactor to define the operating window and to investigate the Si deposition kinetics were completed.
Technologies that will enable the private sector to manufacture and widely use photovoltaic systems for the generation of electricity in residential, commercial, industrial, and government applications at a cost per watt that is competitive with other means is investigated. Silicon refinement processes, advanced silicon sheet growth techniques, solar cell development, encapsulation, automated fabrication process technology, advanced module/array design, and module/array test and evaluation techniques are developed.
Several areas of silicon material preparation were addressed including silicon production and purity, thermodynamics, kinetics, mechanisms, particle formation and growth, deposition in fluidized bed reactors, and chemical vapor deposition. Twenty-two papers were presented.
Statistical models developed to define the most likely sources of photovoltaic (PV) array failures and the optimum method of allowing for the defects in order to achieve a 20 yr lifetime with acceptable performance degradation are summarized. Significant parameters were the cost of energy, annual power output, initial cost, replacement cost, rate of module replacement, the discount rate, and the plant lifetime. Acceptable degradation allocations were calculated to be 0.0001 cell failures/yr, 0.005 module failures/yr, 0.05 power loss/yr, a 0.01 rate of power loss/yr, and a 25 yr module wear-out length. Circuit redundancy techniques were determined to offset cell failures using fault tolerant designs such as series/parallel and bypass diode arrangements. Screening processes have been devised to eliminate cells that will crack in operation, and multiple electrical contacts at each cell compensate for the cells which escape the screening test and then crack when installed. The 20 yr array lifetime is expected to be achieved in the near-term.
Balmer emission lines from cataclysmic variables often have nearly equal intensities rather than the rapid decrement predicted by simple nebular theory. Traditionally, this has been interpreted in terms of local thermodynamic equilibrium emission from a dense gas with small volume located just above the accretion disk. It is shown that the intense radiation field within a close binary system can affect excited state populations and optical emission in ways which allow a relatively low density gas to closely mimic the high density situation. In at least one case, the old nova V603 Aql, the emitting gas has a low density and nearly fills the orbital plane of the system. If this is characteristic of other systems, then the determination of orbital parameters and masses of cataclysmic variables from emission line radial velocities, as well as the prediction of soft X-ray emission from accreting binaries, will be affected.
Several on line and off line data processing techniques are used to remove interfering signals due to ground clutter, aircraft, instrumental effects, and external transmissions from the desired atmospheric echoes of Mesosphere Stratosphere, Troposphere (MST) radar. The on line, real time techniques are necessarily simple in order to minimize processing delays. This algorithm examines the individual Doppler spectra which are computed every two to four seconds (for oblique antenna beams). The total spectral power in each individual spectrum is computed by summing all the spectral points. If this integrated power increases from one spectrum to the next by a factor greater than a preselected threshold, then that spectrum is not added to the spectral sum. Succeeding spectra are compared to the last acceptable spectrum. Only a certain maximum number of spectra are allowed to be rejected in succession.
Winter mesospheric echoes are observed between about 55 and 80 km when auroral absorption is present during daylight hours. Relatively steady auroral absorption during sunrise and sunset periods causes a distinct onset and decay signature in mesospheric echo occurrence. The echo onset and disappearance time are shown versus height by the inclined lines for four different dates. The more vertical lines give the visible sunlight height/time curves for both sunrise (SR) and sunset (SS). The data is combined and replotted to give the morning onset height and the afternoon disappearance height as a function of solar zenith angle. Echoes are not observed at the lowest heights in the morning until the solar zenith angle is less than 90 deg. The afternoon echoes at the lowest heights also start to disappear as soon as the solar zenith angle exceeds 90 deg, implying that the solar component which sustains the mesospheric echo is screened by a layer extending up to about 60 km. The morning echo at 73 km onsets near the time of visible sunrise, but in the afternoon the 73 km echo lasts well past visible sunset.
Signal processing for Mesosphere-Stratosphere-Troposphere (MST) radar is carried out by a combination of hardware in high-speed, special-purpose devices and software in a general-purpose, minicomputer/array processor. A block diagram of the signal processing system is presented, and the steps in the processing pathway are described. The current processing capabilities are given, and a system offering greater coherent integration speed is advanced which hinges upon a high speed preprocessor.