Eco-friendly recycling of end-of-life silicon solar panels for reuse in photovoltaic applications

A novel process for extracting tungsten from photovoltaic tungsten-based busbars scrap based on molten salt electrolysis.

Abstract The rapid global expansion of photovoltaics has renewed attention on the material and environmental implications of large-scale deployment. Improving material efficiency is essential to meeting climate targets by reducing resource use and embodied emissions. This study analyses changes in crystalline silicon photovoltaic (PV) module performance between 2008–2012 and 2020–2024 using specifications from 320 commercial products. The median power-to-weight ratio increased from 10.5 W kg -1 to 19.1 W kg -1 (82 % improvement), while the power-to-area ratio rose from 135.3 W m -2 to 219.5 W m -2 (62 % increase). The carbon intensity of module production declined by 72 %, from 0.61 kgCO 2 /W to 0.17 kgCO 2 /W. In 2024 alone, these efficiency gains avoided approximately 19.3 Mt of material demand and 201 MtCO 2 of emissions. Unlike model-based projections, this work uses real-world product data and links efficiency gains to avoided material use and implications for high-intensity materials such as glass and aluminium. The results show that advances in PV module design have enabled rapid capacity growth without proportional increases in resource and emissions burdens, underscoring the importance of decarbonising foundation industries and planning for end-of-life circularity.

Silicon solar panels play an important role in the transition to a carbon-neutral energy system. Silver (Ag), a core yet nonrenewable material in silicon solar panels, faces increasing scarcity with the surge in solar panel production and end-of-life (EoL) volume. We report a synergistic oxidative-coordination strategy for efficient silver recovery from EoL panels. This approach eliminates the use of toxic mineral acids and minimizes secondary pollution by harnessing the strong oxidative potential of hydroxyl radicals (·OH) in combination with the coordination ability of ethylenediaminetetraacetic acid (EDTA). Notably, the in situ formation of Ag-Ag2O heterostructures during oxidation promotes enhanced ·OH generation, thereby accelerating silver dissolution. Using this method, complete silver leaching is achieved within 60 min, while closed-loop regeneration of EDTA2- is enabled through chloride-induced precipitation. Life cycle assessment and technoeconomic analysis revealed significant reductions in energy demand, greenhouse gas emissions, and water consumption compared with conventional methods, alongside nearly 126% greater process profitability. This work establishes a sustainable and industrially viable Ag recovery pathway, addressing critical bottlenecks in EoL silicon solar panel waste management.

In PMS/Fe 2+ , high-valent Fe( iv is generated, which converts PMS to singlet oxygen ( 1 O 2 ) and sulfate radicals (SO 4 ˙ − ). These reactive species oxidize Ag 0 to soluble Ag + , enabling rapid and efficient silver leaching from end-of-life silicon solar cells.

ABSTRACT With the increasingly large volumes of silicon solar panels being decommissioned worldwide, we urgently need to come up with a cheap and efficient recycling strategy that yields high‐value output materials. A crucial step in such recycling is to delaminate the front and back sheets to access the cells and their metallization. In this work, we demonstrate that the adhesion between the encapsulant and the silicon wafers can be weakened, in a fast and effective way, using a picosecond pulsed near‐infrared laser. The glass and encapsulant are then delaminated from the silicon wafer in a thermomechanical step. This method provides direct access to the silicon emitter and bulk as well as the precious and/or toxic metals on its surface, enabling their recycling. Ablation threshold experiments show that the IR laser mostly interacts with the silicon, thereby indirectly ablating the SiN x anti‐reflective coating. We show that laser pattern and laser setting optimization help strike a balance between effective silicon wafer surface ablation and minimal (submicron thick) contamination from the encapsulant, due to lower heat dissipation into the wafer and encapsulant. The SiN x removal, combined with high potential throughput and low OpEx, sets this process apart from existing delamination techniques. The process described in this paper can be crucial to enable rapid and energy‐efficient recycling of silicon PV modules to high‐purity raw materials with a high recovery rate.

This study investigated the suitability of rooftops in Istanbul for solar panels using a GIS (Geographic Information Systems) based approach. The characteristics of the roofs of approximately 1.3 million buildings in Istanbul, such as slope, area and orientation, solar radiation, were calculated with ArcGIS by Esri software, and the electrical energy they would generate and the carbon footprint (CFP) they would prevent if solar panels were placed on the roof of each building were calculated. Various scenarios were created for the years 2030, 2040, and 2050, and the change in the amount of carbon footprint over the years was analyzed. Istanbul's solar energy potential is 258.59 TWh, and the electricity generation if monocrystalline silicon solar panels are used on rooftops is 29.72 TWh. Since the effect of roof obstructions on the efficiency of solar panels is not considered, PV power generation may be overestimated. Istanbul's total rooftop electricity production has the potential to meet 70% of the total electricity consumption for the year 2023. In addition, a solar building information system has been established to help citizens and policymakers in the future and to raise awareness, including various data such as the solar potential of buildings, the amount of electricity generation, and how much carbon emissions will be prevented, and will be available online soon. This study can contribute to Istanbul reaching its carbon neutrality goals and producing effective results on a global scale.

Sustainable energy practices: Analysis of gases and particulate matter emissions during pyrolysis of polymeric layers of waste silicon solar panels for recycling process

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Abstract Buildings are a key focus of global decarbonization due to their large carbon footprints. New net-zero legislation has increased demand for on-site solar harvesting technologies, such as building-integrated photovoltaics (BIPVs). While vertical silicon solar panels are commonly used in BIPVs, they lack aesthetic appeal and perform poorly due to high solar incidence angles. Luminescent solar concentrators (LSCs) offer improved aesthetics and solar cell utilization; however, they show low system-level efficiency due to top surface losses. To reduce these losses, asymmetric light transmission (ALT) interfaces have been proposed. Prior work has focused on ALT interface solar concentrators under direct irradiance, yet the performance of ALT when integrated within LSCs remains uncharacterized. This research aims to evaluate ALT LSC behavior under direct, diffuse, and ground light for vertical installations. A multi-scale model was introduced to estimate annual energy production, combining spectral- and angular-dependent ALT transmission modeled through comsol, light propagation simulation through the concentrator, and system-level energy estimation. Simulations were conducted for Albany, NY and Phoenix, AZ, comparing four device types: solar concentrators and LSCs with and without ALT. Results show that the ALT LSC investigated does not outperform its plain interface counterpart in either location, due to ALT optimization limited to normal incidence and a narrow wavelength range. Minimal improvements in optical efficiency and spectral response for the ALT interface concentrators confirm the need for broader angular and spectral optimization. This study reinforces the need to close the loop by determining the usefulness of light trapping methods through energy estimation.

ABSTRACT Copper complexes inspired by O 2 ‐activating enzymes have been widely investigated as molecular water oxidation catalysts, capable of facile and reversible O─O bond formation and cleavage under mild conditions. In this study, two copper phenanthroline complexes, namely, Cu(phen) and Cu(dophen), exhibit high turnover frequencies (TOFs) of 74 ± 13 and (5.66 ± 0.29) × 10 3 s −1 for water oxidation, respectively. Moreover, amino acid‐functionalized carbon dots (CDs) were used to support the adhesion of the [Cu] complexes onto the electrode, significantly enhancing the TOFs of (2.80 ± 0.12) × 10 3 and (4.11 ± 0.24) × 10 4 s −1 , respectively, exceeding the activity of photosystem II in nature. Remarkably, the amino acid‐functionalized CDs provide a secondary sphere that mimics the catalytic microenvironment of the copper centre, which promotes proton‐coupled electron transfer and O─O bond formation. Finally, the photovoltaic‐electrolysis (PVE) system was established using CDs‐supported Cu catalysts and commercial silicon solar panels, achieving a high solar‐to‐hydrogen efficiency of 11.59% under the illumination of AM 1.5 G. This represents the most efficient solar‐driven water splitting system based on copper‐based catalysts to date, introducing the biomimetic secondary sphere to a “proton‐rocking” process for water oxidation catalysis and application of the PVE system.

Perovskite-based solar cells (PSCs) have reached efficiencies comparable to those of commonly used silicon solar panels. Despite the promise of PSCs, their efficiency and commercial viability are currently restricted by three main factors: nonradiative charge recombinations on defects occurring within the light-absorbing layer and at its boundaries, limited reproducibility, and upscaling due to widely employed wet deposition methods. To address these issues, we investigated the defect passivation strategy by introducing potassium salt (KCl) during perovskite vapor deposition. We observed effective passivation of the defects upon KCl addition, manifested as an immediate and significant enhancement of the real-time photoluminescence (PL) intensity. The efficiency of passivation is related to the ionic nature of the potassium salt and its flux density. On the other hand, the perovskite's crystallographic structure and texture, as observed from the grazing-incidence wide/small-angle X-ray scattering measurements, showed no significant changes due to KCl doping. Our work provides valuable insight into the possible passivation routes for the vapor-deposited perovskite layers, with implications for various chemical compositions or architectures.

The sun bathes our planet with far more energy than humankind will possibly ever need (> 8,000 times the current demand). Yet, sustainable energy provision is among the most pressing challenges faced today. In order to unlock the vast potential of clean solar energy, we need disruptive technologies capable of efficiently harvesting sunlight, while being deployable at unprecedented scales. Available commercial photovoltaics (PV) can hardly cope sustainably with the sheer scale of this challenge. Silicon solar panels are the major commercial PV, they are based on a very Earth-abundant element, but their fabrication is extremely energy intensive. Conversely, thin film solar panels based on CdTe and Cu(In,Ga)Se2 (CIGS) require far less energy to produce, but some of their constituent elements are quite rare on the Earth’s crust. Hence, in both cases, the short term economic and ecologic sustainabilities are dubious. Recently, an advanced PV concept, called microconcentrator PV [1], has been conceived, which is free from raw materials availability constraints and is based on sunlight absorbers requiring low energy to grow. Additionally, semi-transparent panels could be created, consisting of stripes having width on the order of 100 micrometers [2]. To demonstrate such advanced PV concepts at laboratory scale, research groups have been using optical projection lithography (OPL), generating arrays of Cu(In,Ga)Se2 circles with tens of micrometer diameter. However, OPL cannot be scaled credibly to terawatt deployment. Industrial uptake of microconcentrator PV is only possible with a technique that ensures both high semiconductor quality, and high throughput at capital expenditure comparable to or lower than currently available PVs. Inspired by the research of Gary Friedman on ferrofluid lithography [3], a disrupting microfabrication technique is being pursued within REMAP [5], and e-APP projects [6]. Our intent is to pioneer a method that could be scaled economically to deploy terawatts of microconcentrator or semi-transparent PV [4]. Herein, we outline the progress made on the formulation of magnetorheological electrolytes: bifunctional fluids intended for effective reusable masking, from synthesis to application. Acknowledgements The Authors acknowledge funding from the European Commission PathFinder Open programme under grant agreement No. 101046909 (REMAP, reusable mask patterning). This work was also supported by the European Union and by the Italian Ministry of University and Research through the Clean Energy Transition Partnership scheme under grant agreement No. 2022-00327 (TRANSMIT, semi-transparent micro-striped thin-film photovoltaics for energy-harvesting windows). This work was supported in part by the Italian Ministry of Foreign Affairs and International Cooperation under grant agreement No. PGR11541 (e-APP, empowering advanced photovoltaic pioneers). Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or European Innovation Council and SME Executive Agency (EISMEA). Neither the European Union nor the granting authority can be held responsible for them.

The recycling of silicon solar panels is vital to ensure critical material recovery and to sustain the manufacturing of new panels in line with the United Nations Sustainable Development Goals. While various recycling methods based on thermal, chemical, or mechanical separation of the solar panel layers have been studied, a comprehensive thermodynamic and environmental analysis is required to allow holistic comparison within the circular economy framework. Here, such an analysis is performed for four different silicon solar panel recycling processes. First, the processes were simulated in HSC chemistry TM to analyse the flows of exergy. Subsequently, a Life Cycle Assessment (LCA) was conducted to understand the environmental benefits and drawbacks of each method. Combined Exergy-LCA analysis showed that a slightly less exergy-efficient process, namely pyrolysis can ultimately has the lowest environmental impact out of the four processes. In contrast chemical treatment of the encapsulant exhibited comparably worse performance due to its increased resource consumption. On the material level, high-value material recovery, if realized, could be thermodynamically and environmentally advantageous. The recovery methods presented here could be further improved if heat integration or the use of natural solvents would be considered. These unique findings demonstrate that weighing exergy - Life Cycle Analysis trade-offs across different recycling approaches could navigate future developments towards more sustainable solar panel recycling. Therefore, such an approach is recommended over solely focusing on material recovery. • Thermodynamical and environmental analysis of silicon solar panel recycling. • Four different separation methods of silicon solar panel materials simulated. • Critical material and intact panel-parts recovery evidenced as beneficial. • Sustainability highly dependent on the method of recycling.

American manufacturing is seeing a renewal, which is needed to boost jobs in America, particularly in the middle and manufacturing base of the country. The ongoing tariff situation emphasizes the importance of protecting domestic manufacturing. There is U.S. congressional agreement, in principle, to bring back manufacturing to the United States. However, given how the global trade and manufacturing space has shifted in the last four decades, it may not be a comparative advantage to manufacture low margin and labor-intensive products. Officials in the current U.S. Administration have stated that manufacturing of socks and T-shirts is not necessarily in the interest of the United States, but focusing on value-added products is essential. While silicon chips, solar panels, and batteries are key items of interest, advanced textile materials such as those that find applications in industrial products and composites, products that can save human lives, and products for protecting the environment are highly-valued items that cater to national security.

Evaluation of environmental footprint: Life Cycle Assessment of Laboratory-scale thermal and chemical processes used for materials extraction from waste silicon solar panels

This paper proposes a hybrid energy-harvesting chip that utilizes both radio-frequency (RF) energy and solar energy for low-power applications and extended service life. The key contributions include a wide input power range, a compact chip area, and a high maximum power conversion efficiency (PCE). Solar energy is a clean and readily available source. The hybrid energy harvesting system has gained popularity by combining RF and solar energy to improve overall energy availability and efficiency. The proposed chip comprises a matching network, rectifier, charge pump, DC combiner, overvoltage protection circuit, and low-dropout voltage regulator (LDO). The matching network ensures maximum power delivery from the antenna to the rectifier. The rectifier circuit utilizes a cross-coupled differential drive rectifier to convert radio frequency energy into DC voltage, incorporating boosting functionality. In addition, a solar harvester is employed to provide an additional energy source to extend service time and stabilize the output by combining it with the radio-frequency source using a DC combiner. The overvoltage protection circuit safeguards against high voltage passing from the DC combiner to the LDO. Finally, the LDO facilitates the production of a stable output voltage. The entire circuit is simulated using the Taiwan Semiconductor Manufacturing Company 0.18 µm 1P6M complementary metal–oxide–semiconductor standard process developed by the Taiwan Semiconductor Research Institute. The simulation results indicated a rectifier conversion efficiency of approximately 41.6% for the proposed radio-frequency-energy-harvesting system. It can operate with power levels ranging from −1 to 20 dBm, and the rectifier circuit’s output voltage is within the range of 1.7–1.8 V. A 0.2 W monocrystalline silicon solar panel (70 × 30 mm2) was used to generate a supplied voltage of 1 V. The overvoltage protection circuit limited the output voltage to 3.6 V. Finally, the LDO yielded a stable output voltage of 3.3 V.

Implementing lighting solutions with sunlight can diminish electricity consumption in buildings. Since buildings are accountable for 30% of yearly global greenhouse gas emissions and 40% of energy utilization, concentrating on emissions from this sector is vital for gathering greenhouse gas reduction goals. A cutting-edge solution has been devised in the form of a stack of luminescent solar concentrator (LSC) sheets, employing a grouping of three vibrant fluorescent dyes. This improvement could serve as a dynamic and adaptable design to conventional silicon solar panels, assisting in incorporating solar energy systems in urban landscapes. This work delves into the impact of a solar luminescent panel on the visual well-being and impression of participants who generously volunteered. The main purpose of this work is to evaluate the authority of solar panels on the aesthetic tinting of windows found on college campuses. An analysis is assessed to examine the impact of color palettes on students’ perception of the university. Several performance examination metrics were employed to evaluate the effect of the luminescent panel. The proposed study, conducted on different campuses, attained a maximum color rendering index (CRI) of 91, a user rating on color grading of 98, and an average CCT (CCT AVG) of 9874.

Effective resource recovery and reuse are important to overcome the enormous challenges associated with waste photovoltaic (PV) module management and limited raw material supply, but these processes are severely hampered by the inefficient and unprofitable recovery of current technologies. This article presents a unique approach to recover high‐purity silicon from end‐of‐life (EoL) silicon solar panels through a two‐step process combining acid etching and alkaline etching, which does not involve the use of hydrofluoric acid (HF). Firstly, a preliminary delamination process is carried out on EoL PV modules using thermal treatment to recover Al frames, tempered glass, Cu tapes, and silicon wafers. Then, for the removal of impurity Ag, the better acidic process between HNO3 and H2SO4 is compared. Finally, by comparing different etching processes, it is found that NaOH can not only efficiently remove the impurity Al but also replace HF for removing antireflective coating. Therefore, a two‐step chemical process combining acid and alkaline immersion significantly reduces the main impurities Ag and Al. The process is greener and has less silicon loss than HF, eliminating potential human health and environmental issues associated with HF. In addition, the purity of silicon recovered by this process is up to 4N grade.

以生活中常见的硅光太阳能板作为桶探测器，研究鬼成像方案，旨在显著降低鬼成像系统的经济成本，并研究其在不同采样条件和不同恢复算法下的成像性能，探索硅光太阳能板在鬼成像领域的更多可能性。实验采用二值分布的随机动态散斑图样，经投影仪投影至物体，物光经硅光太阳能板转换为电压值，由示波器测量并读出。太阳能板产生的序列电压即为鬼成像的桶测量信号，而随机动态散斑图样构成测量矩阵，作为参考信号。将测量矩阵的伪逆矩阵作用于桶测量信号，即可重构出物体图像。实验结果显示：在40%采样率下，伪逆算法能够获得高质量成像。同时，与CCD（charge coupled device）作为桶探测器的实验进行比较分析。该鬼成像技术高效且经济，在环境监测、智能交通、航空航天等领域具有光明的应用前景。