Aligned with the 2030 vision for renewable energy in Iran, Mana Energy Pak has successfully localized the photovoltaic value chain knowledge by establishing panel manufacturing plants in Khomein. Using the latest global technology, the company has increased its panel production capacity to 2,300 MW annually.
Clarity, Mana Energy Pak's solar panels are produced in various types, including monofacial and bifacial, with power outputs ranging from 300 to 700 watts. These panels are manufactured per the latest technologies such as TOPCon and PERC.
The photovoltaic value chain includes various stages of solar panel production, such as the extraction and refining of silicon, converting polysilicon into ingots and wafers, designing, manufacturing, and testing solar cells, and finally assembling the cells into photovoltaic modules. In today's world, where the need for clean and renewable energy is more pressing than ever, solar panels play a vital role in meeting this demand.
A solar panel directly converts sunlight into usable electricity using photovoltaic technology. The silicon cells within the panel absorb solar energy units (photons), releasing electrons and generating an electric current. With continuous improvements in efficiency and reductions in production costs, solar panels are becoming increasingly efficient and cost-effective. A solar panel typically consists of various components, including solar cells, a back sheet, EVA (ethylene-vinyl acetate) sheets, anti-reflective glass, and a junction box.
This knowledge enterprise company, as the first producer of solar cells in Iran, has established production lines for various types of cells, including Half-Cell and Full-Cell, using precise and advanced equipment at its Khomein site. Currently, Mana Energy Pak's solar cell production capacity stands at 1,500 MW per year. The produced cells undergo rigorous testing and automatic monitoring to ensure performance quality in compliance with global standards.
The solar cell is the primary component used in photovoltaic panels responsible for converting solar energy into electricity. The manufacturing process of these cells involves the use of advanced stages and technologies. Typically, the main raw material for solar cells is silicon, which, as a semiconductor, has the capability to convert light into electricity.
The production of photovoltaic cells begins with the extraction of silicon dioxide from mines, which is then converted into metallurgical silicon in an electric arc furnace and subsequently into polysilicon. The resulting polysilicon is processed into ingots and silicon wafers of various sizes. After inspecting the wafers, a texturizing process is performed to reduce reflection and enhance light absorption on their surface. Next, the diffusion process is carried out, where additional layers of semiconductor materials such as phosphorus and boron are added to the silicon wafers. These layers create an electric field within the cell. Finally, metal electrodes (busbars) are placed on the cell to collect and transfer the generated electric current.
At Mana Energy Pak's solar panel manufacturing facility, the processes for producing silicon ingots and wafers and converting them into photovoltaic cells have been localized based on the latest global methods and necessary standards. The current production capacity of this facility for silicon wafers is 1,500 megawatts per year. This demonstrates Mana Energy Pak's capability to meet domestic demand and even export solar panels. Additionally, by utilizing the latest global technologies in the production stages, the company is continuously enhancing efficiency and reducing production costs.
Polysilicon, the primary material used in the manufacturing of solar cells, undergoes several processes, including the Czochralski process, to be transformed into monocrystalline silicon ingots. Pure silicon is melted in furnaces to form a molten state. This molten silicon is then solidified into silicon ingots through crystallization and crystal growth processes. In the wafer manufacturing plant, these silicon ingots are cut into wafers of specific dimensions using fully automated machinery.
These pieces are then sliced into wafers less than 200 microns thick using specialized machinery and wire saws coated with fine diamond particles. These wafers serve as the primary material for solar cells.
These stages of silicon ingot production form the foundation for the manufacturing of solar cells and panels. Continuous improvements in these processes lead to enhanced efficiency and quality of the products, which helps in expanding the use of solar energy.
The production of solar cells and panels involves several distinct stages, each requiring advanced materials and technologies. Mana Energy Pak aims to fully develop the photovoltaic industry value chain in Iran and has already made significant strides in this direction. Notable efforts include the establishment of the first EVA sheet production unit and the production of various metal pastes, such as silver, in Khomein.
Among the essential materials and technologies required in the production of solar panels are the EVA protective layer, anti-reflective glass, aluminum frame, junction box, ribbons, silver paste, and aluminum paste
The EVA (Ethylene Vinyl Acetate) sheet is a crucial component in the structure of a solar panel, playing a vital role in protecting the solar cells. As a transparent and flexible plastic polymer, EVA is typically placed between the front glass layer and the solar cells. This protective layer serves essential functions, such as shielding the cells from moisture, water, impacts, and potential vibrations, as well as enhancing the adhesion of the panel's components.
In the production of solar panels, silver paste, and aluminum are essential materials for connecting and collecting the electrical current generated by the solar cells. Silver paste and aluminum paste are conductive materials used as busbars on the front and back of the solar cells. These pastes play a crucial role in ensuring efficient electrical conductivity and performance of the solar panels.
