Japanese company launches solar module manufacturing at Houston-area plant

solar plant

TOYO Solar LLC has begun operations at its solar module manufacturing facility in Humble, Texas. Photo via Pexels.

A local subsidiary of a Japanese solar equipment manufacturer recently began producing solar modules at a new plant in Humble.

TOYO Co. Ltd.’s TOYO Solar LLC subsidiary can produce 1 gigawatt worth of solar modules per year at a 567,140-square-foot plant it leases in Lovett Industrial’s Nexus North Logistics Park on Greens Road. TOYO Solar’s next phase will accommodate 2.5 gigawatts’ worth of solar module manufacturing. The subsidiary eventually plans to expand manufacturing capacity to 6.5 gigawatts.

For now, TOYO Solar operates only one assembly line at the Humble plant. Once TOYO Solar has five assembly lines up and running, it could employ as many as 750 manufacturing workers there, according to Connect CRE.

TOYO says the plant enlarges its U.S. footprint “to be closer to the majority of its clients, meet the demand for American-made solar panels, and contribute to the growing demand for secure, sustainable energy solutions as demands on the grid continue to rise.”

Last month, TOYO purchased the remaining 24.99 percent stake in TOYO Solar to make it a wholly owned subsidiary. TOYO entered the Houston-area market through its 2024 acquisition of a majority stake in Solar Plus Technology Texas LLC.

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Freyr Battery acquired Trina Solar’s 5 GW solar module manufacturing facility in Wilmer, Texas. Photo courtesy of Freyr Battery

Clean energy co. abandons plans for Georgia factory after buying Texas plant

In The News

A clean energy company is abandoning a plan to build a giant electric battery factory in Atlanta's suburbs after it shifted to buy a solar panel plant in Texas.

Freyr Battery told officials on Thursday that it wouldn't build a $2.6 billion plant that was supposed to hire more than 700 people, after sending a Jan. 21 letter to the Coweta County Development Authority announcing its plans to end the project.

The factory would have built batteries to store electricity produced by renewable sources and release it later, company officials said. It would have been the second-largest battery factory worldwide when it was announced in 2023. But Freyr, a startup founded in 2018, never began construction on the 368-acre site.

Freyr, which moved its corporate headquarters from Norway to Newnan in part to maximize its eligibility for the U.S. tax benefits of President Joe Biden's climate law, said it was shifting its focus to a newly opened solar panel factory that it bought last year for $340 million from top Chinese solar panel maker Trina Solar. The facility is located in Wilmer, Texas (Dallas County).

“We are so grateful for the support and partnership we found in Coweta County and throughout Georgia," Freyr spokesperson Amy Jaick wrote in a statement, "However, as noted in our December release, we are focusing at the moment on the solar module manufacturing facility in Texas.”

The Newnan Times-Herald first reported the story, saying Freyr senior vice president of business development Jason Peace met Thursday with local officials. Peace told Coweta County Development Authority board members that the decision was driven by rising interest rates, falling battery prices, a change in company leadership and a shift in its goals, authority President Sarah Jacobs wrote in an email Friday.

The Georgia Department of Economic Development said the state conveyed a $7 million grant to buy a site for Freyr in Newnan, about 35 miles southwest of Atlanta. Department spokesperson Jessica Atwell said the state and company are “working together” to ensure the money is “repaid expeditiously.” Freyr may also owe money to Coweta County.

“Georgia’s incentives process protects the Georgia taxpayer, and when a company’s plans change, that process ensures discretionary incentives are repaid," Atwell said in a statement.

Jacobs said planning for the project made Coweta County a stronger candidate for future projects.

The company had said it planned to build battery factories in Norway and Finland but said in November that it will try to sell its European business. The company also said it was terminating its license for technology to make batteries, paying $3 million to the company it was licensed from.

Tom Einar Jensen, then the company's CEO, told investors in August that it had grown difficult to raise money to make batteries because of a surplus of Chinese batteries being produced at lower costs. The company said it was switching its strategy into businesses that would allow it to raise cash, including solar panel manufacturing. The company saw its cash on hand fall from $253 million at the end of 2023 to $182 million on Sept. 30.

Georgia Gov. Brian Kemp has targeted recruitment of the electric vehicle industry.

Korean firm SK Innovation built a $2.6 billion battery plant in Commerce, northeast of Atlanta and hired 3,000 workers, but later laid off or furloughed some workers.

Hyundai Motor Group has started production at a $7.6 billion electric vehicle and battery plant near Savannah, with plans to hire 8,500 workers. Electric truck maker Rivian revived its plans to build a plant east of Atlanta after a $6.6 billion loan from the Biden administration.

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Houston researchers propose model to scale e-waste recycling

critical research

The “missing link” in critical minerals may have been in our junk drawers all along, according to new research from the University of Houston.

Jian Shi, an associate professor in the UH Cullen College of Engineering, and his team have unveiled a new supply chain model that aims to make e-waste economically viable and could help make large-scale recycling possible.

Shi, along with professor Kailai Wang and graduate researcher Chuyue Wang, published the work in a recent issue of Nature. Their study outlines how gold, lithium and cobalt from discarded electronics can be kept circulating in the U.S. through the process of “urban mining.” It was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) through the Vehicle Technologies Office.

The team’s research found that e-waste is the fastest-growing solid waste stream in the world. When waste from smartphones or tablets is left unmanaged, the devices can leak hazardous waste and pose significant fire risks due to aging batteries. Additionally, when they are shipped off to foreign landfills, the U.S. loses the potential to recycle or reuse the critical minerals left inside.

“A lot of people have iPads or old iPhones sitting in their drawers right now, and that’s a waste of a critical resource,” Shi said in a news release. “Urban mining allows us to extract the same high-value materials found in traditional mines without the environmental destruction. More importantly, it helps secure our domestic supply chain for the technologies of tomorrow.”

According to UH, recycling e-waste has not succeeded in the U.S. due to a fragmented recycling system, in which manufacturers, collectors and recyclers operate separately, driving up costs.

The UH team's research looks to change that.

In the study, the researchers modeled streamlined recycling efforts by mapping the interactions between manufacturers and independent recycling markets. Their dual-channel closed-loop supply chain (CLSC) model identified how these players can transition from competitors to partners, which can distribute profits more equitably and make recycling efforts more financially attractive.

According to UH, the research has particular significance due to the growing demand for electronic vehicles and their batteries.

“We can improve the performance of the entire recycling ecosystem and make the profit distribution more balanced,” Wang said in the release. “This ensures that the materials we need for EVs and advanced electronics stay right here in the U.S.”

“By making recycling work at scale, we aren’t just cleaning up waste,” Shi added. “We’re building a foundation that benefits both our national security and our economy.”

1PointFive signs latest deal, shares update on $1.3B carbon removal project

DAC deal

Houston-based 1PointFive, a subsidiary of Occidental Petroleum Corp., has secured another buyer of carbon dioxide removal credits for its $1.3 billion STRATOS project as it moves toward operation.

Bain & Company, a Boston-based consulting firm, has agreed to purchase 9,000 metric tons of carbon dioxide removal (CDR) credits from the direct air capture (DAC) facility over three years, according to a news release. DAC technology pulls CO2 from the air at any location, not just where carbon dioxide is emitted.

The deal is Bain's first purchase of DAC removal credits. The company has developed a program that helps clients purchase carbon credits from a range of carbon-removal technologies.

"We are proud to partner with 1PointFive and add them to our portfolio of engineered carbon removal technologies," Sam Israelit, Bain’s chief sustainability officer, said in the news release. "Their track record for developing DAC technology, coupled with their deep understanding of what it takes to deliver large-scale infrastructure projects, uniquely positions them to be a leader in this emerging segment.”

“We believe this agreement demonstrates continued momentum for the solution while supporting the development of vital domestic infrastructure,” Anthony Cottone, president and general manager of 1PointFive, added in the release.

Bain joins others like Microsoft, Amazon, AT&T, Airbus, the Houston Astros and the Houston Texans that have agreed to buy CDR credits from STRATOS.

The Texas-based STRATOS project is being developed through a joint venture with investment manager BlackRock and is designed to capture up to 500,000 metric tons of CO2 per year. The U.S Environmental Protection Agency approved Class VI permits for the project last year.

1PointFive says STRATOS is "progressing through start-up activities." The company shared in a LinkedIn post that Phase 1 of the project is expected to go online in Q2, with Phase 2 ramping up through the remainder of 2026.

Houston researcher develops efficient method to cool AI data centers

cool findings

A University of Houston professor has developed a new cooling method that can remove heat at least three times more effectively from AI data centers than current technologies.

Hadi Ghasemi, a distinguished professor of Mechanical & Aerospace Engineering at UH, published his findings in two articles in the International Journal of Heat and Mass Transfer. The findings solve a critical issue in the growing AI sector, according to UH.

High-powered AI data centers generate huge amounts of heat due to the GPU and operating systems they use with extreme power densities, which introduce complex thermal challenges. Traditionally, cooling methods, like microchannels, which use flow and spray cooling, have had limitations when exposed to extreme heat flux, according to UH.

Ghasemi’s research, however, found a more effective way to design thin-film evaporation structures to release heat from data centers and electronics at record performance.

Ghasem’s solution coupled topology optimization and AI modeling to determine the best shapes for thin film efficiency, ultimately landing on a branch-like structure—resembling a tree.

The model found that the “branches” needed to be about 50 percent solid and 50 percent empty space for optimum efficiency, and that they could sustain high heat fluxes with minimal thermal resistance.

“These structures could achieve high critical heat flux at much lower superheat compared to traditionally studied structures,” Ghasemi said in a news release. “The new structures can remove heat without having to get as hot as previous removal systems.

Ghasemi’s doctoral candidates, Amirmohammad Jahanbakhsh and Saber Badkoobeh Hezave, also worked on the project. The team believes their results show the impact of a physics-aware, AI design and can help ensure reliability, longevity and stability of AI data centers.

“Beyond achieving record performance, these new findings provide fundamental insight into the governing heat-transfer physics and establishes a rational pathway toward even higher thermal dissipation capacities,” Ghasemi added in the release

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