US turns former nuclear plant into low-energy polysilicon facility

The United States is repurposing the former Phipps Bend Nuclear Plant site in Hawkins County, Tennessee, into a major polysilicon manufacturing hub aimed at producing solar-grade polysilicon with an annual capacity of 16,000 metric tons, projected to increase to 20,000 metric tons within four years. This output is sufficient to supply about 11 gigawatts of solar cells yearly. The redevelopment leverages existing infrastructure from the abandoned nuclear project, including a high-voltage transmission interconnect and favorable zoning, facilitating large-scale industrial use. Highland Materials, a new polysilicon manufacturer, will anchor the site with advanced manufacturing facilities, supported by a long-term lease secured through Pivotal Manufacturing Partners. The project received $255.6 million in federal tax credits under the Inflation Reduction Act. Highland Materials plans to implement an innovative, energy-efficient aluminum–silicon alloy smelting process that significantly reduces energy consumption to 20–40 kWh per kilogram of silicon, much lower