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					Elkem Solar plant
- Ground-breaking technology for cost leadership


Johan Svensson, Project Director
Kristiansand, 18 June 2009
    Elkem Solar is contributing to the
    future of the PV industry



                                                          Creating
                                                           future




                      Lower                                           Less energy
                  production cost                                     consumption
                                                      Equivalent
                                                    product quality




2   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    Outstanding safety records

    •    No lost time injuries


    •    16 injuries needed assistance from medical personnel; the last injury
         was 240 days ago


    •    The H figure (injuries per 1 million working-hours) ended at 5.78 for
         the entire project, a record by Norwegian standards


    •    The Elkem Solar Project was executed using 2.8 million working hours


    •    5 500 individuals people have undergone the safety training required to
         be allowed to work at the plant




3   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    Elkem Technology Park, Kristiansand

          Elkem Solar AS
          Elkem Carbon AS
          Elkem Silicon Solutions
          Elkem Technology and Projects




4   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    The very essence of Elkem’s long history of
    developing new materials and technologies
     From Søderberg…                                      … to solar




     Engineer Carl‐Wilhelm 
     Söderberg




5   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    Elkem
    – a long history of silicon leadership

     1919 :         Søderberg electrode patented. 2 000 kW FeSi furnace started up with
                    world's largest electrode (850 mm dia.)

     1962 :         Regular silicon metal production starts

     1980:          Started development of solar-grade metal together with international
                    partners, Exxon/Texas Instruments/AstroPower +

     2009:          Start up at the 1st industrial solar plant




6   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    December 2006




7   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    December 2007




8   Orkla Investor Day - Elkem Solar Plant 18 June 2009
    December 2008




9   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     17 June 2009




10   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Elkem Solar Silicon® production process




     1                          2                     3              4                   5




• In-house                 • Three sequential purification steps to reduce impurity   • Ingots cleaned and cut
  production only            levels                                                     into bricks of ~10 kg

• Based on Elkem‘s         • Elkem’s core competencies are high temperature           • Quality control
 core competencies           processes, and process- and equipment design




11   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Plant layout



                              Lab
                                  or               1. S
     Elkem Carbon              tor a-         ( me       mel
                                                              ter
                                  y               tall.
                                                        silic
                                                             on)        2. S
                                                                            lag
                                                                    trea
                               5.                                       tm e
                                  Pos                                        nt
                            tre
                                atm t
                                   ent
                                                                                                   g
                                                  4.                                        hi n
                                                     So                                L eac
                                                  cat lidifi-                     3.
                                                     ion




12   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Step 1: Smelter (metallurgical silicon)

                                                           •   Metallurgical smelting
                                                               process in an electric arc
                                                               furnace where quartz is
                                                               reduced to silicon using
                                                               carbon
                                                           •   Standard Elkem process
                                                           •   Limited risk as regards
                                                               availability and quality
                                                               specification
                                                           •   One furnace




13   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Step 2 i): Slag treatment

                                                           •   Pyrometallurgical slag
                                                               treatment
                                                           •   Liquid silicon is transferred
                                                               from the arc furnace – the
                                                               silicon is solidified and crushed
                                                               after treatment
                                                           •   The main purpose to remove
                                                               boron
                                                           •   Slag furnaces operated in
                                                               different Elkem contexts
                                                           •   Risks mainly associated with
                                                               availability of equipment
                                                               (utilisation) – One production
                                                               line




14   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Step 2 ii): Slag treatment - crushing

                                                           •   The slag-treated metal is crushed
                                                               in a crusher before being sent to
                                                               Leaching (step 3)


                                                           •   The risks are mainly associated
                                                               with availability of equipment
                                                               (utilisation) – One production line




15   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Step 3: Leaching

                                                           •   The hydrometallurgical
                                                               cleaning process is where
                                                               crushed silicon is cleaned
                                                               with acids
                                                           •   The main purpose to reduce
                                                               the level of phosphorus and
                                                               other metallic impurities
                                                           •   Similar process carried out at
                                                               Elkem Bremanger to produce
                                                               Silgrain®
                                                           •   Risks mainly associated with
                                                               availability of equipment
                                                               (utilisation) – one production
                                                               line




16   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Step 4: Direct solidification

                                                           •   Direct solidification of
                                                               granular silicon from
                                                               Leaching (step 3)
                                                           •   The main purpose is to
                                                               further reduce the levels
                                                               of phosphorus and other
                                                               metallic impurities
                                                           •   Process similar to solar
                                                               ingot production
                                                           •   Limited risk related to
                                                               availability and quality
                                                               specification
                                                           •   34 furnaces




17   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Step 5: Post treatment

                                                           •   Ingot from Solidification (step 4)
                                                               sawed into ~10 kg bricks,
                                                               cleaned with acids and quality
                                                               controlled – then packed and
                                                               shipped to customer
                                                           •   The main purpose is to cut off
                                                               parts of ingot that have an
                                                               excessive concentration of
                                                               impurities
                                                           •   Limited risk
                                                           •   Five cutting cells




18   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Laboratory
                                                           •   One of the most advanced
                                                               laboratories in the world


                                                           •   The material in the ingot can be
                                                               tracked from the Si- furnace all
                                                               the way until it is ready for
                                                               shipping to clients


                                                           •   Tests are being taken from each
                                                               ingot


                                                           •   No ingot is sent to Post
                                                               Treatment (step 5) for cutting
                                                               until analyses have been
                                                               performed and qualities
                                                               determined




19   Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Elkem Solar R&D

     Prior to plant no.1:
     •      In-house development of metallurgical processes for the production
            of solar-grade-silicon
     •      Proprietary processes for slag treatment, leaching and the
            solidification of silicon
     •      Development and testing of new technology solutions
     •      Product verification in respect of customers and international
            institutions


     Current focus:
     •      Product development for multi- and mono-crystalline cells
     •      New, improved low-cost process for solar-grade-silicon
     •      Improvement of plant 1 production processes and production
            equipment




20       Orkla Investor Day - Elkem Solar Plant 18 June 2009
     Elkem Solar is contributing to the
     future of the PV industry



                                                           Creating
                                                            future




                       Lower                                           Less energy
                   production cost                                     consumption
                                                       Equivalent
                                                     product quality




21   Orkla Investor Day - Elkem Solar Plant 18 June 2009

				
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