Why is solar panel recycling a key concern in the industrial landscape, and what role does aluminium play?

As early photovoltaic or PV solar panel installations are nearing the end of their operational lifespan, solar panel recycling is turning out to be a central concern. With global solar capacity expansion in process, the focus is shifting toward an efficient and responsible implementation of PV modules after decommissioning. 

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In the past two decades, global installation of PV solar panels has shot up. Most of these were developed to operate for 25 to 30 years. In 2024, global installed capacity exceeded 2.2 TW, with nearly 600 GW added in a single year. As these systems retire, limited recycling infrastructure could lead to a growing volume of electronic waste.

According to the International Renewable Energy Agency (IRENA),   PV modules would likely generate about 1.7-8 million tonnes of waste by 2030. By 2050, it is expected to soar to between 60 and 78 million tonnes, a substantial share of which will consist of aluminium scrap without adequate recovery systems.

In this scenario, aluminium circularity is coming to the forefront, accounting for over 85 per cent of PV component materials like frames and mounting structures. 

Also read: Nearly 8MT aluminium is used in solar photovoltaic – what is happening to its circularity at end-of-life?

Present and projected aluminium usage in solar PVs

Solar module frames and racking systems mainly use the 6-series aluminium. Nearly 8 million tonnes of aluminium were used in the manufacture of PV systems in 2024. Out of this, China alone accounted for 4 million tonnes of its domestic PV capacity. 

By 2030, an additional 4 to 10 million tonnes of aluminium would be required for photovoltaic structures in Europe itself, as a twofold increase is projected in solar PV capacity to more than 750 GW.

The data drawn up by Wood Mackenzie shows that manufacturing 1 MW of PV capacity requires 21 tonnes (approx.) of aluminium. In concentrating solar power (CSP) systems, aluminium intensity is even higher than twice that amount, at approximately 47 kg per kW.

Regulation and technological progress for recycling efficiency

The expansion of recycling infrastructure is creating activity across logistics, processing, engineering and research. Regulatory measures are evolving in multiple regions. The European Union has introduced solar panel recycling into electronic waste regulations. Other nations are designing extended producer responsibility policies.

Recycling efficiency is being reinforced by technological modifications, including higher material recovery rates and panel designs to enable easier dismantling. Digital tracking systems are also being introduced to improve collection and lifecycle management. 

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