A Bright Future: For the Planet and for Solar Panel Recycling
The deployment of solar energy is a key driver in our transition towards a clean, carbon-free future. However, as the solar industry grows exponentially across the globe, so does the concern with PV System end-of-life (EOL) material management, or, what do we do with all the system parts once they are no longer operational.
Earlier this year, we attended the Federation of New York Solid Waste Conference in May, where there was considerable discussion about the state of the PV recycling industry. On one side, we heard concerns from some attendees, wondering what we were doing to avoid panels being sent to landfills once they reached their EOL. On the other side, we saw a lot of excitement and initiatives from e-waste recyclers who are actively learning about and implementing PV recycling to their list of services.
At AC Power, our goal is to revitalize and repurpose existing landfills, not create new ones, and so EOL management for solar panels is an extremely interesting topic for us. This blog post aims to dig into some of the issues surrounding what happens to solar panels once they have reached the end of their useful life, and how, as developers, we can ensure that the sustainability of our projects doesn’t end at decommissioning.
First, some solar facts and stats, and EOL management
A PV system consists of modules, racking structures, and inverters that connect it to the grid. The modules, which make up about half of the system’s materials by mass, are composed of roughly 90% glass and aluminum. The rest of the system includes steel for racking, piles, and trackers; copper and aluminum for wiring; and plastics for electronics and wire housing. Approximately 75% of the 100 GW of installed photovoltaic (PV) capacity in the United States has been deployed since 2016. With typical solar arrays lasting 25 to 35 years, and many lasting even longer, most systems will not reach the end of their life (EOL) for several decades. Still, EOL considerations are in effect for some early installations as well as replacements due to weather damage, installation errors, or manufacturing defects.
The reuse or refurbishment of modules, inverters, racking equipment, and other components is always preferable to recycling. There are many creative ways to reuse old panels. One examples of reuse is using older panels to power things that require less energy being produced than an entire home or a solar farm such as sheds, camper vans, and small electronics used while camping. Another reuse possibility is to make use of solar panels inherent insulation properties. Greenhouses, chicken coops, dog houses and even eco-friendly homes can all benefit from being built with old solar panels. Nonetheless, reusing the panels will not always be a possibility, but the market for PV Recycling is evolving and we’re excited to be following trends at this stage.
Understanding Recycling Processes
To further understand some of the main challenges and opportunities in the market, we spoke with Robert Nicholson, Senior Manager of Sustainability for the Solar Energy Industries Association (SEIA), (of which AC Power is a member) who explained the basics of the solar panel recycling process. The recycling process itself typically involves two main methods: thermal and mechanical separation. The thermal method involves shredding and smelting, though no smelters currently operate in the US. Mechanical separation, more common and efficient, reclaims materials for reuse in various industrial applications.
Interestingly, despite the heavy focus on recovering metals from solar installations, the most challenging material to recycle is glass, which constitutes about 80% of a panel's weight. The issue lies in economics: glass is so inexpensive to produce that recycling it often doesn’t make financial sense. However, there are other uses for glass that are much more economically interesting, such as for pozzolans, an aggregate for concrete manufacturing, or breaking it down into sand to help preserve eroding coastlines. Universities and private industries are developing scalable solutions for glass reuse, so efforts are underway to prevent significant amounts of the material from ending up in landfills.
Another significant challenge is ensuring the integrity of recycling operations and to address this, SEIA has established the Solar Recycling Partners Program. The program rigorously vets and inspects recycling companies to ensure they meet industry standards and commitments. Thus far, they have 10 fully vetted companies that together can recycle 10 million panels annually – a number expected to double over the next year. None of these recyclers are yet at capacity, showing how proactive the industry has been.
Solar Recycling in Action
With no federal regulations currently mandating the recycling of photovoltaic (PV) modules at the end of their useful life, some municipalities are taking proactive steps by strengthening their decommissioning requirements. These municipalities are now requiring developers to include detailed plans for recycling solar panels as part of the decommissioning plan, which is a crucial component of the development process and essential for securing municipal approval.
For example, the project we developed in the Town of Niagara- a 13 MWDC community solar project sited on a closed landfill- adheres to strict guidelines on photovoltaic recycling in accordance with local law. This law mandates a convenient, safe, and environmentally sound system for recycling PV modules, minimizing hazardous waste, and recovering commercially valuable materials.
To meet these requirements, AC Power partnered with SOLARCYCLE (a partner in SEIA’s Solar Recycling Program) to develop a comprehensive Stewardship Plan that ensures the responsible decommissioning and recycling of all solar modules and installation components at the end of their lifecycle. Under this plan, SOLARCYCLE handles everything from setting up takeback locations within the County, to processing and recycling the materials at their facility in Odessa, Texas. The recovery project includes detailed sustainability reporting, reverse logistics, and other metrics that guarantee accentuality along the supply chain. AC Power is eager to build on this experience as more municipalities prioritize end-of-life management for solar installations.
Looking Ahead
Robert Nicholson from SEIA pointed out that the while disposal of solar panels in landfills is considered safe, the more we can repurpose or recycle, the better. He also highlighted that, when it comes to environmental and social responsibility, the solar industry – and renewables in general – is already held to higher standards than other energy producing industries ever were. And since the market is preparing for the future, the industry is ahead of the curve rather than making up for past damages. At AC Power we’re building on the expertise gained from working with forward-thinking municipalities like Niagara County and collaborating with trusted partners through SEIA's initiatives. We are paying attention to developments and want to be part of the solution!
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