Researchers from the University of New South Wales (UNSW), Gdansk University of Technology and Polish Academy of Sciences have collaborated to study the value of purifying key components from end-of-life solar panels ideally for reuse in new solar panel manufacturing.
The scientists, Olivia Bowen, Anna Kuczynska-Lazewska, Rong Deng and Jacek Kluska examinied the differences in solar panel composition between different models and manufacturers to initially evaluate the ability of the modules to be recycled.
“Decommissioned silicon solar panels were collected from across Australia. Some of the modules were taken from the field because of technical failure or system upgrades whilst the remaining panels were new panels donated to the study by solar manufacturers,” the scientists said.
The twelve modules made by German, Chinese, South Korean and US manufacturers were dismantled to take samples of the aluminium frame, glass, and solar cell from compositional analysis.
The study results, published in a Science Direct paper titled Beyond assumptions: Experimental characterisation of end-of-life photovoltaic panels composition for recycling in Australia, found that despite variability in material composition among the different panels, the key components are all recyclable, though with important considerations.
They found aluminium frames (96.3% – 98.3% aluminium) are suitable for recycling, potentially saving significant primary energy costs, however, surface coatings containing high amounts of sulphur decrease purity and economic value.
The glass components meet the criteria for feedstock in new glass manufacturing, despite trace elements of antimony, lead, chromium, and iron.
“Antinomy, added to solar panel glass to enhance light transmission, is classified as a hazardous substance subject to regulatory limits. The study found that antinomy levels in solar panels can exceed threshold limits and consequently, recyclers may require special license and monitoring process to handle antimony-contained glass safely,” the study concludes.
Laminate analysis also showed high crosslinked ethylene-vinyl acetate (EVA) with low crystallinity levels (below 17%), indicating continued protective function even in end-of-life panels.
“Understanding EVA structure and crosslinking degree is also crucial for optimising delamination methods for future research. It would be beneficial to the delamination process if the EVA analysis were to be carried out before to determine the delamination approach,” the researchers said.
Lastly solar cell composition was found to vary significantly between the manufacturers, with an industry trend of decreasing silver content in more recent panels.
“The copper content also varied depending on the cell technology of the panel. This trend warns recyclers of potential decreases in future economic revenue, as silver comprises up to 47% of a panel’s recoverable value,” they said.
The presence of lead and tin in all samples also highlighted a need for careful handling of hazardous materials, especially in wastewater disposal.
Barriers
The study concluded variability between panels produced by different manufacturers could pose barriers to effective commercial recycling processes.
“The recyclability of each of the components depends heavily on the composition with both aluminium and glass being reduced in value as a result of contamination with various impurities,” the researchers said.
“Observed trends in the reduction of silver content in newer panels will affect the recycling revenue and therefore recyclers need to be aware of the changing revenue potential of the process as more low silver content panels are recycled.”
Recycling glass was found to be “heavily dependent” on the glass not being contaminated with other metals, with the researchers warning that crushing or milling panels is likely to contaminate the glass with silver and copper reducing its value and potentially making the largest component of the panel non-recyclable.
Despite the variability between panels the researchers advise that simple mechanical removal of these components, “even disregarding the cell laminate would prevent large amounts of waste from going to landfill.”
The researchers hope their comprehensive, experimentally derived data can inform researchers and companies designing recycling processes as well as policy development, which they note at a federal level in Australia is absent.
The insights could optimise recycling strategies to assess the economic viability of recycling processes for the growing photovoltaic waste stream in Australia and similar markets.
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