Reshaping the Module: The Path to Comprehensive Photovoltaic Panel Recycling

A facile crush-and-sieve treatment for recycling end-of-life photovoltaics

The shift towards renewable energy mix has resulted in an exponential growth of the photovoltaic (PV) industry over the past few decades. Parallelly, new recycling technology developments are required to address the incoming volume of waste as they gradually approach their end-of-life (EoL) to realize the concept of a circular economy. Typical recycling processes involve high-temperature burning for separation and release of the PV cells for metal recovery processes. However, this thermal process generates gaseous by-products that cause serious health and environmental issues. Eschewing the need for burning, we demonstrate a simple crush-and-sieve methodology to strategically aids the separation of polymeric and metallic contents. The proposed approach showcased the efficient size-selective separation and generated polymer- and metal-rich fractions. More than 90 % of the total polymer present within the studied wastes was found to be retained in larger sized-particle fractions (F1 and F2). Metal content analysis highlighted the enrichment of highly valuable silver into the smallest sized-particle fraction (F4), accounting up to 70 % and 80 % of total silver present respectively for EVAc and MP. The benefits ripe through this simple crush-and-sieve method offers an attractive pathway for PV recycling process to obtain metal-rich fractions and allow focused recovery of valuable materials through an environmentally friendlier manner.

Circular economy priorities for photovoltaics in the energy transition

Among the many ambitious decarbonization goals globally, the US intends grid decarbonization by 2035, requiring 1 TW of installed photovoltaics (PV), up from ~110 GW in 2021. This unprecedented global scale-up will stress existing PV supply chains with increased material and energy demands. By 2050, 1.75 TW of PV in the US cumulatively demands 97 million metric tonnes of virgin material and creates 8 million metric tonnes of life cycle waste. This analysis leverages the PV in Circular Economy tool (PV ICE) to evaluate two circular economy approaches, lifetime extension and closed-loop recycling, on their ability to reduce virgin material demands and life cycle wastes while meeting capacity goals. Modules with 50-year lifetimes can reduce virgin material demand by 3% through reduced deployment. Modules with 15-year lifetimes require an additional 1.2 TW of replacement modules to maintain capacity, increasing virgin material demand and waste unless >90% of module mass is closed-loop recycled. Currently, no PV technology is more than 90% closed-loop recycled. Glass, the majority of mass in all PV technologies and an energy intensive component with a problematic supply chain, should be targeted for a circular redesign. Our work contributes data-backed insights prioritizing circular PV strategies for a sustainable energy transition.