Speeding up solar power

Many renewable energy projects, once a site is found and construction begins, deal with a lot of land, a lot of labor and a lot of building materials and equipment. Imagine an entire range of rolling hills that slowly becomes a wind farm, or an empty expanse of desert badlands gradually filling up with row upon row of 10,000 or more photovoltaic panels. The finished product can be a majestic sight, sure, but before the control room fires up and power starts flowing onto the grid, there's still the matter of all that construction that has to happen first.

Companies that can cost-effectively speed up this process while still producing a reliable and long-lasting product could probably clean up with the renewable energy market performing as strongly as it is right now.

A colleague of mine, James Montgomery of RenewableEnergyWorld.com introduced me to Alion Energy (pronounced like the words "a" and "lion"). This company's process builds solar photovoltaic panels into a sort of ramp structure that uses fewer materials to put together than other methods, and the entire process is done with robots.

And why not use robots? Similar processes using robots are already used to lay traintracks or build sidewalks. Alion's president and CEO Mark Kingsley is a veteran of ABB's robotics unit, Trina. 

During construction, the "Rover" installation robot (seen above, courtesy to Alion Energy) travels along a concrete railing built for the project that also serves as the mounting for the solar panels. To begin with, Rover is loaded up with solar panels. Rover fixes the solar panel legs into the concrete railing with a high-strength, high-durability epoxy that is used in bridge construction. The panes and their preattached mountings come next, attached to the legs. With that, the robot moves on to the next solar panel.

One of the big advantages to this approach is using fewer materials. The concrete that the railings are shaped out of is cheap and can be acquired on a local basis. There's no large panes of glass to worry about transporting, unbroken, to the site. No bulky metal frames or fasteners are needed.

Labor costs, similarly, can be reduced this way. No trenches have to be dug, no nuts and bolts need tightening. Plus, the robots don't get fatigued by repetitive work in areas where the sun beats down with a lot of heat, either.

As far as scalability goes, Alion told RenewableEnergyWorld.com that the benefits of the approach only increase when applied to bigger solar projects. Essentially, the bigger the project, the more money can be saved. The railing system can be used in areas with high winds or prone to storms, and in rocky areas or urban brownfields, according to the company.

With Rover's job done and the solar power feeding onto the power grid, another robot takes over to perform maintenance duties. A smaller robot named "Spot" (above) performs automatic cleaning of the mounted solar panels so dust and dirt do not accumulate and cause a loss of generation efficiency. Spot has his own solar-powered battery and his own solar panel, and when he isn't working, he "lives" near one end of of the concrete rail system before sliding across the panels to perform his duties. Spot can also use a hedge-clipping attachment for vegetation management, where and when it is needed.

Automated, efficient construction could potentially mean a lot for the renewable energy sector when and where it can be used. Increasing a generation technology's speed-to-market can only make it more attractive to the prospective investor — the people without which a project can't reach fruition.

Our changing generation mix

As an online editor, I handle stories every day of new wind farms going up or some local dignitaries pulling the switch for a new solar energy project. You read stories that use phrases like "dash for gas" or "war on coal," but absorbing stuff like this day by day has a way of numbing you to the big picture.

The big picture is that things are changing in a big way. I realized recently that the way I think about the generation mix in the U.S. is seriously out of date. I did a mental check. "OK, so natural gas is about 25 percent, nuclear is a steady 20 percent, coal is like half at least, right?"

Wrong.

New data from FERC shows the picture is changing drastically. Especially natural gas, coal and renewables. Wind and solar — which used to be relegated to a tiny sliver of the pie, or else an asterisk or an "other" — are contributing more than 5 percent of the total generation mix of the country.

Even more surprising perhaps is coal, which has fallen to less than 30 percent of the pie. What's replacing it, largely, is natural gas, which is now 42.37 percent of the mix.

Certainly I knew that coal-fired power plants were retiring. I hadn't missed those announcements. Indeed, sometimes it felt like the only coal stories I ever filed were those concerning coal power plants shutting down or switching to natural gas.

Nuclear, known for its reliability, is sticking at a steady 20 percent. However, given the potential of small modular reactors and the NRC granting new licenses, even just a few new projects going online could change that figure in the future.

Even unexpected generation technologies, like geothermal energy, seems to be showing some growth with more than 147 MW of new capacity being brought online last year — an increase of 5 percent from 2011.

I first started to notice this when FERC released a recap of the power generation that came online in 2012. Half of that new generation had been renewable energy. Some analysts I spoke to at the time considered this a fluke. They said there was no way that this could sustain itself. But FERC keeps reporting the data, and if anything the numbers look like this trend is speeding up. Coal is out, natural gas and renewables are in.

Things are changing in statistically significant ways. When you watch it every day, like energy experts tend to do, sometimes you can lose track of just how fast it's moving.

Land of the rising sun runs increasingly on solar power

UPDATE: Shortly after this blog was written, Reuters reported that Japan will shortly introduce a plan to wean itself off of nuclear energy entirely by as soon as 2030. This development will doubtless result in an entirely new energy policy and eventually an entirely new generation mix for the country.

In many spots around the globe, power producers and utilities are looking to deconcentrate their grids away from large, centralized power generators and steer them more toward distributed generation. There are cons to this approach, but the benefits are attractive, at least in theory.

While some countries have the luxury of carefully weighing these pros and cons, there is one country that's being forced by current events to decentralize, and rapidly, just to keep the lights on.

New research indicates that post-Fukushima Japan is now the world's third-largest solar energy markets, with nearly 5 GW of installed solar capacity. Germany and Italy, respectively, are the first and second. In some ways, though, this is a return to form for Japan rather than a new development.

In the 1990s and the early 2000s, Japan was the world leader in solar. Due to the cancelation of programs that backed solar (as a result of the government response to the "Lost Decade" depression in that country) and an accompanying shift toward nuclear power, Japan took its eye off the ball when it came to solar energy.

Then, of course, came the earthquake, the tsunami and the Fukushima disaster.

(Photo credit: Shutterstock)

Since then, Japan's government has taken a second look at solar, and added more than 1 GW of solar capacity last year. The majority of this new generation is grid-connected, with all the benefits and drawbacks that adds.

With the adoption of new solar-friendly regulations and generous tariffs, companies across Japan's economic spectrum have announced plans to set up solar parks and install rooftop solar arrays on their properties. To boot, Japan is also one of the world leaders in manufacturing solar cells, modules and other key materials that support the solar energy supply chain.

Can a country replace a highly productive nuclear fleet with solar energy? That question raises further questions, but it's certainly a daring strategy and it will be interesting to watch unfold.

It's (trade) war between the U.S. and China

By Jeff Postelwait
Online Editor

Things are heating up again between the U.S. and China, and this time the trouble has to do with international trade and the equipment used to capture solar energy. For several years now, U.S. energy companies have complained they can't compete with the "flood" of cheap solar energy gear that's coming from China and flooding the U.S. and world markets. Companies facing financial troubles or bankruptcy, like Solyndra for one, are looking for a scapegoat, and many of them are pointing at China.

In response, the U.S. Department of Commerce is launching an investigation into these practices. This "anti-dumping" investigation led Commerce to explore the option of levying duty fees, or tariffs, against the Chinese-made solar goods. Just last year, China sold more than $3.1 billion worth of solar cells and panels in the U.S., so it's easy to see why it's referred to as a "dump." While nothing is final yet, Chinese firms are hopping mad, some American firms are pointedly silent, and trade groups with interests worldwide just want everyone to get along.

This isn't the first time Commerce has threatened to impose such tariffs, or indeed carried them out. There were tariffs taken out against Chinese electric blankets, of all things, not too long ago. But protectionism is always controversial, and in today's global economy it's not always easy to know if one country's tariffs might not also harm companies within that same country's borders. Some American energy companies that use Chinese-made solar parts might stand to lose profits if they have to buy them at higher margins, for example.

If the tariffs go through, Chinese companies will be left to either raise their prices in hopes of turning a (now lowered) profit, or else move their manufacturing centers outside of China to dodge the tariffs. Some companies that might be subject to future tariffs could be poised to do so. Suntech Power Holdings, for example, which could face tariffs as high as 31.2 percent, has regional headquarters in Switzerland and the U.S. as well as China, and could conceivably shift operations to those or other countries. Mexico and Taiwan are two spots that Suntech, and other companies like it, might consider.

Suntech, perhaps predictably, says it opposes any barriers to trade at any point along the solar power supply chain. But what are American companies saying? As I write this, they're mostly pretty quiet, and I'd assume happy. But there are signs I might be assuming wrong.

Whether an energy company in America is smiling or frowning about these potential tariffs depends greatly upon where they sit on the solar supply chain. The guys who shape steel and silicon into panels might be happy, but the folks who actually slap the finished panels onto rooftops, for example, might be less so.

We should also not forget that there are other firms in other countries who'd like to do business making solar farms in the U.S. Companies based in Germany, Spain and elsewhere are feeling the squeeze as China has tightened its grip on the U.S. market these past few years. They might also stand to benefit from tariffs, perhaps. Assuming they are pointed squarely at Chinese firms, that is.

The U.S., for its part, claims that all it wants to do is level the playing field. But can it really be level at this point? By now everyone understands the problems that China, also known as "The World's Factory," can cause the rest of the world with their massive workforce and low labor costs. They have the power and willingness to produce goods and ship them to market at costs few other countries can match.

Still, there is the little matter of international trade laws. While I am by no means an expert on those, I assume the U.S. Commerce Department is. So I will be watching what comes out of their offices in the coming weeks, as I'm sure the Chinese will as well. It should be interesting. Stay tuned for more.