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Production of low-cost solar-grade silicon by reduction of SiF4 gas with sodium: Technical and industrial developmental status

To meet increasing demand for electrical power using solar photovoltaics, millions of tons of solar-grade silicon costing <$20/kg will be needed. Low-cost solar-grade silicon can be mass produced by burning Na metal in an atmosphere of pure SiF4 gas—an exothermic, fast, and complete reaction. SRI International routinely uses reactors that can produce at rates >20 metric tons per year (mty), and has licensed the technology to several companies. The Si product is completely separated from the by-product NaF by leaching or melt separation. With the direct use of industrially available Na, B and P levels in the Si product are <1 ppm. Using purified Na results in Si with dopant levels as low as 20 ppb. Experimental ingots grown have resistivity of 1 to 30 Ω·cm, with >100 Ω·cm when purified reactants were used. The purity, electronic parameters, and solar cell efficiency of 15% indicate that this silicon is of solar grade and can be a key contributor in developing solar power markets.