An international research team has developed a high-pressure water-jet delamination recycling method for end-of-life (EoL) photovoltaic modules. The technology was evaluated at pilot scale for its ability to recover high-purity silver (Ag), copper (Cu), silicon (Si), glass, and polymer fractions.
“This study was initiated to investigate and upscale advanced delamination-based recycling pathways for c-Si PV modules,” the researchers said. “This work evaluates high-pressure water-jet delamination-based recycling, which mechanically separates laminated module layers while minimizing cross-contamination between material fractions. It aims to contribute to the development of scalable EoL PV recycling solutions by addressing key gaps in current recycling approaches.”
The experimental work was carried out as part of the Quasar Horizon Europe project, which focuses on advancing circular solutions for EoL PV modules through the development and demonstration of two recycling technologies. According to the research group, the proposed approach provides a separation pathway that improves material recovery compared with conventional mechanical recycling processes.
The process begins with a delamination step, in which a high-pressure water jet separates the strongly bonded layers of glass, encapsulant, solar cells, and backsheet. The technique produces a high-purity glass fraction, while the detached mixed material fraction is subsequently separated from the process water through filtration. The filtered water is then recirculated within the system, reducing water consumption and supporting a more sustainable recycling process.
In the next step, the mixed fraction – containing polymer materials, silicon cell fragments, and metallic interconnectors – undergoes further processing. Established density-based mechanical separation techniques, including wet shaking-table separation, are used to divide the material into heavy and light fractions.
“Metallic wires and busbars were further separated using eddy-current separation methods,” the researchers said. “The silicon-rich cell fragment fraction was then processed through hydrometallurgical treatment to recover silver. Silver was recovered through electrochemical deposition, followed by melting and conversion into spherical particles.”
Following the completion of the process at the experimental facility, the recovered materials were subjected to analytical characterization. The results showed that the recovered silver achieved a purity of up to 97%, while the recovered smart wire contained 78% Cu, 17% bismuth (Bi), and 4.5% tin (Sn).
The recovered silicon fraction still contained residual impurities, including 22.33 mg/kg phosphorus (P), 13.33 mg/kg silver (Ag), 10.67 mg/kg tin (Sn), and 4.83 mg/kg calcium (Ca). The recovered polymer fraction was dominated by inorganic contamination, with approximately 81% silicon (Si), 6.8% aluminum (Al), and 5.3% titanium (Ti).
“For silicon, the recycling route recovered material with residual metallization and coatings, indicating the need for further refining for high-value reuse,” the researchers concluded. “The impurity contents and profiles highlight the importance of selecting appropriate processes based on downstream purification strategies and intended end uses.”
The research findings were presented in “Material recovery and characterization from end-of-life photovoltaic modules using water-jet delamination,” published in Solar Energy Materials and Solar Cells. The team included scientists from Norway’s Foundation for Industrial and Technical Research (SINTEF) and Germany’s circular economy company LuxChemtech.
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