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