Market and general Conditions
Economic framework
In the first half of 2008 the global real economy showed itself to be largely unaffected by the financial crisis triggered in the USA. Even though important international banks had already been pulled into the wake of the US mortgage crisis, the economy was still expanding in the first quarters of 2008. Growing financing problems and the lack of liquidity at major banks then also had an impact on the real economy, starting in the second half of the year 2008. The 5.1 per cent growth of the worldwide GDP that was still predicted at the end of 2007 could not be achieved. The global economy grew by as little as 2.7 (previous year: 3.9) per cent, according to the figures of the German Institute for Economic Research (Deutsches Institut für Wirtschaftsforschung = DIW). The main drivers of this growth were mainly China, India and Russia.
Material usage rate down. In the year under review material use accounted for € 454.1 million (previous year: € 333.7m), which is equivalent to 49.2 (previous year: 49.6) per cent of total output. The rate of material usage has thus declined by 0.4 per centage points.
Due to strongly rising raw material prices and owing to capacity bottlenecks, the trend towards price hikes continued in the year under review. We were able to mitigate, and in some cases even to eliminate this trend. We managed to do this through economies of scale but, above all, through the conclusion of long-term supply contracts, larger purchasing quantities, capacity reservations and clearer supplier structuring for strategically important products, some of which extend all the way to the year 2012. The increasing raw material prices refer mainly to consumables: To be mentioned in this context are aluminium, copper, and silver as components of frames, cables, cell connectors, pastes as well as semi-finished products such as raw graphite and also organic and inorganic chemicals. Silicon prices within the framework of long-term contracts were fairly stable in the course of the period under review.
The supply of raw materials and consumables to our manufacturing sites was assured at all times during the year 2008. Thus, the contractually secured quantity of silicon under a supply contract concluded in the first quarter of the year with the Korean silicon producer, DC Chemical Co. Ltd. (DCC), would be enough to produce wafers with an imputed total power output of 600 MW. Furthermore, we concluded another contract for the delivery of solar-grade silicon valued at 580 million US dollars up to the year 2016 that will support wafer expansion in Freiberg and Hillsboro.
For module production in South Korea another long-term contract was concluded in the year under review with the Korean wafer manufacturer, Nexolon Co. Ltd., which is designed to secure the basic supplies for the new module production facility in South Korea as of the year 2009. The contract provides for the supply of 420 MW worth of wafers for seven years.
Internally we strengthen our procurement position regarding the input products for wafers and cells by way of our own integrated production. Around half of the wafers we produce go into the group’s internal cell and module production. In this way we secure the solidity of our business and our growth.
Group-wide organization guarantees efficiency. Purchasing is organized via our group-wide procurement management at our production location of Freiberg, Germany. Purchasing managers in the USA and South Korea back up group-wide buying. The working contents of the purchasing teams are organized by merchandise categories, thus guaranteeing efficient and short internal information channels.
Quality and environmental claim – Supplier Capital. According to an internal supplier survey dating from August 2008, some 77.5 per cent of our suppliers are ISO 9001 certified in the area of quality management and 30 per cent are ISO 14001 certified in the area of environmental management. In addition, we conclude quality assurance agreements with our suppliers. In this way we minimize our own inspection of incoming goods, reduce the risk respecting required environmental and quality standards along the entire supply chain, cut costs as a result, and substantiate the quality and environmental claim of the SOLARWORLD brand vis-à-vis the customer.
Group growth secured through raw material activities. Silicon, the most important raw material for the solar industry, was subject to violent price fluctuations in the year under review. The solar power market By way of long-term silicon contracts, some of them concluded last year, we were able to minimize the impact that the volatilities had on our purchase prices. With our own silicon production and our recycling activities, we additionally managed to further stabilize our raw material position and costs. We secured our 2008 wafer production as well as further expansion plans by using three independent pillars (1st silicon production, 2nd recycling, 3rd external purchasing).
Own silicon production started. Under the coverage of SUNICON AG we are pooling our group’s own raw material activities. Within the framework of the Joint Venture, JOINT SOLAR SILICON VERWALTUNGS GmbH (jssi) with Evonik Degussa GmbH (solarworld: 49 per cent), we evaluate and develop processes in industrial silicon production with regard to their feasibility and economy.
In 2008 jssi took up its silicon production. The so far unique jssi process based on the use of mono-silane is extremely energy-efficient because, in comparison with conventional silicon production, it saves up to 90 per cent of the required energy. The favorable energy efficiency balance was one of the reasons why, in the course of the year under review, SOLARWORLD AG received the German Sustainability Award in the “Production” category. The brand
Another advantage: The investment costs for this process are clearly lower than those for the Siemens process employed so far. The newly developed precipitation process is protected by four patents. All rights are held exclusively by jssi, whose general conditions are laid down in a master agreement. On the one hand, Evonik Degussa GmbH provides the input product, mono-silane, and on the other acts as a partner (in the context of the Joint Venture) in building the precipitation plant for the subsequent production of solar-grade silicon under the brand sunsil®. The Joint Venture thus ensures our supply of inexpensive silicon even at times when silicon is expensive and scarce. On 8 August, industrial production was started with a planned nominal capacity of 850 tonnes per year. After the start-up of the plant the production volumes were increased step by step until the end of the year so that, in 2008, we were able to make available some 46 tonnes of solar-grade silicon from our own internal raw material source for the first time. For further upgrading of the sunsil® product, three compaction processes were developed which will enter production as early as in 2009. Regarding the purchase of the input product, mono-silane, Evonik Degussa GmbH, jssi and SOLARWORLD AG concluded 10-year contracts. In this way we secure the very basis for our silicon production over the long term.
In an additional process development we are working on the production of solar-grade silicon from processed metallurgical silicon. The cleansing process investigated by the Joint Venture, SCHEUTEN SOLARWORLD SOLICIUM GmbH, at the Freiberg site is a new development. By means of different process steps, boron and phosphorous are eliminated and the silicon is processed as an input product for subsequent wafer block production.
Recycling to secure the supply of raw materials. With our broad range of recycling activities we hold a leading market position worldwide. Our activities range from by-products of solar and semiconductor production and processing via wafer and cell scrap all the way to the recycling of all commercially available solar modules. Production residues from wafer and column manufacture are also completely recycled.
Cells and modules made from recycled wafers meet the same quality and performance criteria as modules from non-recycled raw materials. We have succeeded in increasingly automating the internal recycling processes thus making them more cost-efficient. For example, in 2008 we used a fully automatic fine grain etching and sorting machine. Another advantage: The energy employed in recycling is substantially lower than that in primary silicon production. The costs of the preparation of secondary silicon amount to between ten and 50 per cent of the raw material purchase prices (excluding spot market transactions), so that, in 2008, recycling also made a contribution to cutting the average raw material costs of the group.
In 2008 we succeeded in optimising the inspection of incoming merchandise and the relevant analysis processes and in implementing new preparation technologies: As a result a wider spectrum of recycling material has become usable.
In the year under review we maintained the recycling result of about 900 tonnes as well as a constant material quality – in spite of the increasingly complex raw materials mix and the greater efforts required. SolarMaterial works at full capacity utilization. All in all, a nominal etching capacity of 1,200 tonnes per annum is available.
As a service to external customers we offer recycling from the preparation of raw materials provided by the customer all the way to block and wafer production. About one third of our recycling sales are generated in this way. However, the priority is on our own raw materials supply within the group. Our recycling contributes about 20 per cent to the raw materials supply of the group.
Above and beyond this commitment within the group, we are among the co-initiators of the PV CYCLE association founded in 2007 and located in Brussels. www.pvcycle.org The tasks of this association include the creation of a voluntary European system for the return of solar power modules as well as the guarantee of expert recycling. PV CYCLE represents some 70 per cent of European module and solar cell producers today. Through its activities, the association preempts the legal duty of redemption that has been announced creating manufacturers’ responsibility for the entire product life cycle based on their own initiative. Opportunities
Closed value chain in the SOLARWORLD Group
Source: Basic Chart: PV CYCLE





