Case Study: EMIX achieves 15% energy savings and 30% higher throughput in PV silicon casting with COMSOL Multiphysics

EMIX uses multiphysics simulation to optimize its cold crucible continuous casting process for the manufacture of photovoltaic-quality silicon

Emix, part of Grupo FerroAtlántica, manufactures photovoltaic-quality silicon using an inductive cold crucible continuous casting (4C) process and faced the twin challenges of lowering silicon production costs and increasing purity while optimizing crucible design and process parameters. To tackle this, Emix used Comsol’s COMSOL Multiphysics software to model the electromagnetic, heat transfer, flow, and phase-change behavior in their process.

Comsol implemented coupled multiscale electromagnetic and 3D continuous-casting simulations to optimize crucible geometry, inductance/impedance, annealing and cooling zones, and pulling rates. The Comsol-enabled studies reduced pilot testing, improved electrical efficiency, found crystallization parameters that balance production rate and ingot stress, and indicated about 15% energy savings and roughly 30% higher pulling rates in theory, with good agreement between simulation and pilot experiments.

Emix

Julien Givernaud

Research Engineer