A U.S. view of silicon production processes

One of the objectives of the Low-Cost Solar Array Project is the demonstration of the practicality of processes for producing silicon, suitable for fabricating solar cells for terrestrial applications, at prices less than $14/kg. Approaches being investigated are related to a metallurgical silicon/silane/silicon process, a metallurgical silicon/dichlorosilane/Siemens-type process, and a silicon tetrachloride-zinc reduction process. There is a great probability that the first process will yield semiconductor grade Si at a price less than $14/kg. The second process appears to be capable of providing polysilicon with a purity equivalent to the present commercial semiconductor grade silicon at a price of about $20/kg. An important part of the program is the investigation of the effects of impurities on the performance of solar cells.