The United States repurposes an old nuclear site to manufacture polysilicon for the production of 11 gigawatts of solar cells annually.
Highland Materials to Revolutionize Polysilicon Production in Tennessee
Highland Materials, a new polysilicon manufacturer, is set to establish a groundbreaking 16,000 MT polysilicon plant at the former Phipps Bend Nuclear Plant site in Hawkins County, Tennessee. This innovative project, anchored by Highland Materials, will usher in a new era of domestic polysilicon production, aiming to reduce reliance on global supply chains dominated by countries like China.
The plant will initially produce 16,000 metric tons of solar-grade polysilicon annually, with plans to expand to 20,000 metric tons within four years. This production scale equates to 11 GW of solar cells annually, a significant contribution to the solar industry.
Highland Materials' choice of the Phipps Bend site was strategic. The location offers exceptional power infrastructure, being situated within the Tennessee Valley Authority (TVA) transmission network, and an environment prepared for large-scale, high-precision manufacturing. This setting supports the energy-intensive, advanced manufacturing needs of the project.
The project benefits from $255.6 million in Qualifying Advanced Energy Project (Section 48C) tax credits, reflecting recognition of its technological and strategic importance for the U.S. domestic solar manufacturing supply chain.
Partnership with Pivotal Manufacturing Partners, who provide industrial real estate and site development expertise at Phipps Bend, is critical for operationalizing the innovative facility. Pivotal Manufacturing has secured a long-term ground lease with Highland Materials, taking over 140 acres in Hawkins County.
Highland Materials' proprietary technology produces polysilicon more environmentally-friendly than current technologies. The new production process is expected to significantly reduce the plant's environmental footprint. Moreover, the process is more energy-efficient than conventional silicon manufacturing methods, using only 20-40 kWh to produce one kilogram of polysilicon, well below industry norms.
The quality of the polysilicon produced by Highland Materials remains ultra-high, ensuring the production of high-quality solar cells. This advancement in polysilicon manufacturing in the U.S. is made possible by a modernized, scalable production platform embedded in a uniquely suited infrastructure environment, making U.S.-based polysilicon a viable and strategic domestic supply source for solar and semiconductor industries.
[1] Highland Materials Press Release [2] Pivotal Manufacturing Press Release [3] TVA Press Release [4] Inflation Reduction Act Information [5] U.S. Department of Energy Information
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