WAZIPOINT Engineering Science & Technology: Future of Used Solar Panels

Monday, September 8, 2025

Future of Used Solar Panels

Future of Used Solar Panels


The Future of Used Solar Panels: Reuse, Recycling, and Secondary Markets

The solar photovoltaic (PV) revolution is transforming global energy systems, offering a clean and renewable solution to climate change and resource depletion. Yet, with more than 1 TW of cumulative global solar capacity surpassed in 2023, the first significant wave of PV modules is rapidly approaching its end-of-life (EOL) stage. This shift has catalyzed urgent interest in sustainable solutions for managing decommissioned panels, from innovative reuse to advanced recycling, and the expansion of secondary markets that can unlock residual value. How countries and industries address the lifecycle of solar panels beyond their initial use will define the circularity, economics, and true sustainability of solar energy in the coming decades.

This report examines the evolving trajectory for used solar panels, providing a thorough exploration of global reuse strategies, recycling methods and technologies, the development of secondary markets, and the integration of innovations and regulatory frameworks shaping this space. Particular attention is devoted to leading countries-such as the EU, USA, China, Japan, South Korea, Australia, and India-whose policies, pilot projects, and regulatory models are setting the pace for global adoption. The report presents environmental, economic, and technological dimensions, and profiles companies and initiatives driving the industry toward a circular future. To support comparative analysis, a table summarizing key initiatives by technology, country, and organization is included, followed by detailed, analytical paragraphs expanding on each area.


The Solar Panel Lifecycle: From Manufacturing to End-of-Life

Understanding the solar panel lifecycle is crucial for framing reuse and recycling strategies. Typically, a solar panel is designed for a service life of 25-35 years, with most manufacturers guaranteeing a performance of at least 80% after 20 to 30 years. However, in practice, many panels are replaced sooner due to technological upgrades, regulatory shifts, or infrastructure repowering. This growing volume of EOL modules is projected to accelerate, with IRENA estimating that global cumulative PV waste could reach nearly 80 million metric tons by 2050, and Statista projecting up to 60 million metric tons under some scenarios. The majority of this waste will stem from crystalline silicon modules, which currently dominate the market.

The challenge lies in turning this future waste into a resource, supporting the global shift toward a sustainable, circular economy. Key lifecycle phases include:

·         Design and Manufacturing: Emphasizing circularity and recyclability in initial design.

·         Operation and Maintenance: Maximizing efficiency, repair, and partial repowering.

·         End-of-Life (EOL) Management: Encompassing reuse, refurbishment, recycling, and secondary market integration.

Attention to each stage, especially EOL, determines the environmental footprint and economic recovery of materials-critical for ensuring solar’s green credentials remain intact over the long term.


Reuse Strategies for Used Solar Panels

Concepts and Motivations

Reuse extends the value of PV modules by granting them a second life, either through direct redeployment, refurbishment, or as replacement parts in operational systems. Reuse helps delay the entry of modules into the waste stream, lowers economic and material costs associated with new manufacturing, and provides affordable solar solutions for markets with lower performance demands.

Approaches and Methods

1.    Direct Reuse or Redeployment: Used panels that retain sufficient efficiency and structural integrity can be directly redeployed in less demanding environments, such as off-grid systems, rural electrification, or developing markets-thus serving critical energy needs at a low cost78.

2.    Refurbishment and Repair: This involves the active repair or replacement of degraded components-such as inverters, junction boxes, or wiring-followed by functional and safety testing. Refurbishment can occur at dedicated facilities or through in situ maintenance programs at solar farms.

3.    Repowering Projects: Large-scale solar plants, particularly in Europe and North America, increasingly pursue repowering by replacing only the most degraded panels or system components, while integrating reused or upgraded modules for added capacity. This practice reduces waste, extends asset lifespans, and optimizes land use.

4.    Modular Reuse and Repurposing: Solar panels, even those underperforming for grid-fed applications, can be repurposed for micro-generation, educational projects, temporary installations at festivals or disaster sites, and other creative uses.

5.    Quality Control and Certification: Programs and platforms are emerging to standardize the evaluation and certification of reused modules for safety and performance, minimizing risks of malfunctions or inefficient redeployment.

Market Platforms and Examples

The rise of digital secondary marketplaces, such as the EnergyBin exchange, facilitates B2B transactions in used or surplus PV hardware. EnergyBin alone listed more than 5.4 million modules (2.13 GW) for resale between January 2020 and December 2023, with a remarkable 282% increase in used modules listed for resale since 2020710. Notably, 95% of these modules were new “excess stock” originating from overordering, project cancellations, or surplus inventory, while a significant and growing proportion are genuinely used panels following decommissioning or repowering.

EnergyBin and similar platforms enable:

·         The repurposing of panels as replacement parts for operational systems.

·         The deployment of secondhand panels in off-grid and community projects.

·         The integration of used modules in innovative, lower-demand applications (e.g., urban furniture, low-wattage installations)7.

In the U.S., the Smart Energy Council and state governments are also piloting reuse-focused stewardship programs8.

Environmental and Social Benefits

Reuse reduces the environmental impact by delaying resource extraction and waste generation, lowering carbon emissions from manufacturing, and expanding renewable access in underserved communities or developing countries. It also supports job creation and local economic development in refurbishment, testing, and logistics sectors.

Challenges and Limitations

Despite advantages, reuse faces several constraints:

·         Uncertainty about the remaining service life and performance of older modules can deter buyers.

·         Technical incompatibility with newer system components may require adaptation.

·         There is an ongoing need for verified certification systems to ensure safety and reliability.

·         As the market matures, more robust quality assurance standards and traceability mechanisms will be essential.


Recycling Methods and Technological Processes

Why Recycle Solar Panels?

With the projected surge in EOL modules, recycling is essential to prevent landfill pollution, minimize resource extraction, recover valuable materials (e.g., glass, silicon, aluminum, copper, silver), and curb the environmental impact of hazardous substances like lead, cadmium, and tin present in some panel types. Current assessments suggest that up to 95% of a panel’s materials can be efficiently recovered with advanced processes.

The Solar Panel Recycling Process

The typical recycling process comprises several stages:

1. Collection and Logistics: Panels are collected from decommissioned sites, often requiring safe removal and transport due to fragility and hazardous content.

2. Mechanical Dismantling and Delamination:

·         Removal of the aluminum frame and cables.

·         Separation of the glass from encapsulated cells via mechanical cutting or advanced delamination methods.

·         Recovery of glass sheets, which constitute roughly 70-80% of a panel’s mass, and aluminum frames, both readily recyclable using conventional methods13.

3. Thermal and Chemical Treatment:

·         For more thorough resource extraction, panels are subjected to thermal (pyrolysis) or chemical (solvent or acid leaching) processing.

·         This step breaks down encapsulant plastics like EVA and releases silicon wafers, copper wiring, and residual silver contacts.

·         Recovery rates for silicon can reach 80-98%, with similar rates for silver and copper, depending on the technology used.

4. Refinement and Purification: Final recovery, purification, and often upcycling of retrieved materials back into new panels, electronic components, or other products. Advanced methods like laser and electrochemical separation are being developed for higher-value recovery.

Key Recycling Technologies and Innovations

Mechanical Delamination:

·         Preferred for its lower energy use and minimal ecological footprint, mechanical separation preserves the integrity of glass and other materials for higher-quality reuse13.

Robotics and AI Sorting:

·         AI-driven robotic systems are increasingly used to disassemble panels, sort materials by type, and enhance recovery rates. This technology minimizes manual labor, increases speed, and reduces contamination risks. Examples include Norway’s pioneering robotic sorting stations and global pilot projects utilizing advanced sensor and vision technologies for material detection.

Chemical and Solvent-Based Processes:

·         Solvent-based recycling targets the removal of encapsulation layers with selective dissolution, enabling the recovery of high-value silicon wafers, silver, and indium from thin-film panels1312.

·         Thermal delamination remains common but is energy-intensive and can generate harmful emissions, underscoring the push toward greener solutions.

Circular Design Strategies:

·         Companies and research consortia are developing new panel designs for easier disassembly, using release encapsulants or modular architectures that simplify EOL treatment and material recovery.

High-Value Material Recovery:

·         Innovations focus on extracting rare and valuable metals, such as silver, indium, gallium, and high-purity silicon-key for reducing dependency on primary resource extraction.

Industry Pilots and Startups:

·         PHOTORAMA (EU), PV Cycle (Europe/Japan), SOLARCYCLE (USA), and emerging operations in Australia and China are at the forefront, deploying pilot lines and scaling advanced recycling techniques.

Case Study: PHOTORAMA

·         The PHOTORAMA pilot line demonstrates a three-step, high-value recovery process: 1) Disassembly of frames and wiring; 2) Separation of the ‘sandwich’ of glass, silicon cells, and backsheet; 3) Extraction of critical materials for reinjection into new manufacturing streams. The pilot is designed to bridge the gap between recycling and circular industrial production in the EU.

Barriers and Economic Considerations

Although technically feasible, PV recycling faces economic and logistical challenges:

·         Recycling costs ($15-$45 per module in the U.S.) currently exceed landfill charges ($1-$5), due to low volumes, underdeveloped infrastructure, and limited markets for secondary materials.

·         Downcycling (producing lower-value products, like construction aggregate) is still more common than true closed-loop, high-value recycling.

·         Development of efficient and scalable recycling facilities and coordinated logistics networks is urgently needed, especially as waste volumes balloon in the 2030s and 2040s.

Environmental and Socioeconomic Impacts

Recycling EOL PV generates benefits well beyond landfill avoidance:

·         Material Recovery: Reduces pressure on critical raw materials and lessens mining-related environmental degradation. Silicon recovery, for instance, cuts the energy and emissions associated with new silicon production by nearly two-thirds13.

·         Emissions Reductions: By substituting recycled materials in new manufacturing, the circular solar economy can lower lifecycle carbon footprints by up to 70% compared to landfill scenarios.

·         Job Creation: Recycling industries and technology providers create new employment opportunities and stimulate economic growth in regions investing in circular infrastructure.

Leading Companies and Initiatives

·         First Solar (USA): Industry leader in cadmium telluride thin-film panel recycling, with proprietary processes achieving more than 90% material recovery and closed-loop reuse.

·         SOLARCYCLE (USA): Partnering with major solar providers to recycle both crystalline silicon and thin-film panels, aiming for 95% value recovery.

·         We Recycle Solar (USA): Provides automated assessment, recycling, and responsible disposal, using AI-driven solutions for material sorting.

·         PV Cycle (Europe/Japan): Global pioneer operating in accordance with EU WEEE requirements, collecting and recycling PV waste through an extensive logistics network.

·         One Planet Solar Recycling (USA): Specializes in end-of-life modeling and advanced material recovery, including zero-waste targets.

·         PV Industries (Australia): Works with municipalities, businesses, and utilities in route collection, research, and technology development for panel recycling.

·         KGS (Singapore): Operates Southeast Asia’s first automated PV recycling plant, supporting regulatory compliance and sustainability goals for the region.


Development and Growth of Secondary Markets

The Rise of the PV Secondary Market

Secondary markets for PV modules and components serve as vital platforms connecting surplus, used, or repowered panels with new buyers, fostering reuse, repair, remanufacture, and recycling.

Market Drivers

·         Surging Waste and Surplus: Increased decommissioning of large-scale arrays, overordering, project cancellations, and technological obsolescence all contribute to a growing inventory of panels ideally suited for secondary channels.

·         Digital Exchanges: B2B platforms like EnergyBin, PV Buddy, and regional exchanges facilitate transparent transactions, price transparency, and traceability.

·         Policy and Economic Incentives: Regulatory encouragement and rising material values increase the incentive to remarket modules.

·         Resource Scarcity: As prices for silver, copper, and high-purity silicon rise, asset recovery becomes more attractive.

Platform Models and Operations

·         Brokerage and Listing Services: Marketplaces provide sortable listings of new, used, and refurbished modules, with up-to-date price indices and qualitycertifications to assure buyers.

·         Integrated Value-Added Services: Beyond sales, secondary market companies now offer testing, repair, logistics, and recycling services, ensuring a seamless transition along the circular value chain.

·         International Reach: Many platforms operate globally, enabling cross-border movement of panels from mature markets to developing regions or new niche applications.

Current Trends and Impact

EnergyBin statistics highlight continued growth in volume and diversity of offerings, spanning all major technology types. In late 2024, 95% of secondary market inventory was actually new, with project liquidations and technological upgrades releasing “never-used” modules, while used panel listings still saw a 282% increase since 2020 as the market matured.

Although prices in the secondary market often trend lower than in the primary market, certain high-demand or specialty modules maintain premium pricing. Used panels with 80% or greater efficiency are particularly valuable as spares, for off-grid electrification, and in experimental projects.

Challenges and Outlook

Key challenges include:

·         Verification and Traceability: Assuring buyers of quality and compliance with safety and performance standards remains essential.

·         Regulation and Liability: National and regional compliance rules (including extended producer responsibility) require careful management, especially for international shipments.

·         Market Confidence: Ensuring transparency and trust is critical to unlocking secondary market potential at scale.

Yet, as governments and industries increasingly recognize the importance of a robust secondary market in minimizing waste and maximizing asset recovery, investment and participation are expected to accelerate.


Environmental Impacts and Circular Economy Strategies

Environmental Benefits of Circular PV Management

The environmental rationale for strong EOL management in solar is compelling:

·         Reduction of landfill waste and mitigation of toxic material leaching (lead, cadmium).

·         Conservation of critical natural resources and reduced mining.

·         Lower overall lifecycle emissions, supporting national carbon neutrality targets.

·         Enabling of a circular economic model where valuable materials (silicon, silver, copper, aluminum, glass) are recaptured, reused, or reintroduced into manufacturing, often with energy and emissions savings over virgin production265.

Circular Economy Policy Initiatives

From a systems perspective, the circular economy means reimagining all stages of the solar supply chain:

·         Design for Circularity: Creating panels with modular construction, release encapsulants, and easy disassembly for enhanced recyclability.

·         Producer Responsibility: Mandating that manufacturers bear EOL management costs, promoting design incentives for longevity, reusability, and recyclability (as in the EU’s WEEE Directive).

·         Material Tracking and Standardization: Standardized reporting on panel composition, deployed materials, and traceability to facilitate downstream reuse and recycling.

The IRENA and IEA have strongly advocated these approaches, projecting circular management will unlock up to USD 8.8 billion in raw material value and enable millions of tons of critical resource recovery by 2050.

Key Barriers

Significant obstacles remain, including:

·         Unclear or uneven regulations across markets.

·         High operational and logistics costs for collection and transport.

·         Limited confidence among investors and markets in recycled material quality.

·         Need for data sharing and system integration across the value chain26.


National Strategies and Policy Innovations

European Union: WEEE Directive and Producer Responsibility

The EU leads globally with its integration of PV modules into the Waste Electrical and Electronic Equipment (WEEE) Directive since 2012. Under this system:

·         PV panel producers must finance EOL collection, treatment, recovery, and disposal.

·         Mandatory collection, recovery, and recycling rates: 85% of panels to be recovered, 80% to be prepared for reuse or recycled.

·         National registers track EEE and PV modules for compliance and harmonization.

·         Extended responsibility for management and disposal costs falls on producers, with evolving targets subject to periodic review.

The directive has stimulated specialized collection, recycling infrastructure, and service providers, such as PV Cycle and national programs, heavily influencing other countries’ regulatory strategies and multijurisdictional company operations.

United States: Federal Gaps, State Initiatives, and Research Funding

Federal regulation is less prescriptive, but the U.S. DOE’s Solar Energy Technologies Office (SETO) is funding R&D, piloting EOL management practices, and launching the Photovoltaics End-of-Life Action Plan2920. Key features:

·         States such as Washington, New York, and California introduce PV-specific EOL regulations.

·         Recycling costs still exceed landfill costs, though innovation and volume increases could change this paradigm.

·         Incentives under the Inflation Reduction Act and ARPA-E propel domestic manufacturing, reuse, and recycling industries.

Companies like SOLARCYCLE, We Recycle Solar, and One Planet Solar Recycling drive service integration and commercial innovation.

China: National Circular Economy Mandate and Incentive-Driven Recycling

China, the world’s largest PV market, is rapidly rolling out central guidelines and plans to establish a nationwide recycling system by 2025:

·         Strict prohibition on landfilling decommissioned PV equipment.

·         Active support for green design, high-value material utilization, equipment remanufacturing, and robust recycling industry clusters.

·         By 2030, aims to mature a full-process recycling system and industry cluster for PV and wind equipment.

·         Third-party recycling enterprises are encouraged and supported, fueling innovation in logistics and processes.

Japan: Pending Recycling Mandates and Industrial Waste Policy

Facing an anticipated “tsunami” of PV waste in the 2030s, Japan is preparing strong regulations:

·         Solar panel recycling is slated to become mandatory, with penalties for non-compliance expected.

·         Panels will be categorized as industrial waste, requiring recycling akin to automobiles and electronics.

·         Ministry-led expansion of recycling facility capacity and innovation grants.

·         International partnerships and pilot projects, such as the AGC/Tokuyama float glass recycling effort, highlight the country’s technological commitment to closed-loop processes.

South Korea: Extended Producer Responsibility (EPR) and Capacity-Building

South Korea is introducing stringent EPR requirements in 2023, making manufacturers and importers responsible for the recycling of all PV modules, supported by public funding and industry fees:

·         Substantial investment in dedicated PV module recycling facilities.

·         Obligation for companies to pay into recycling funds.

·         Strong framework for tracking and reporting EOL flows.

·         Government targets for expanded PV penetration and domestic recycling infrastructure.

Australia: Product Stewardship and State-Based Bans

Australia’s Product Stewardship Act provides the framework for EOL solar panel management, with the NSW state government and national working groups moving towards a mandatory stewardship scheme:

·         Victoria has already banned PV panels from general landfill.

·         A national draft regulatory impact statement is under development.

·         The Smart Energy Council pilots national collection, reuse, and recycling pilot programs, and industry partnerships are scaling up capacity for secure material recovery.

India: Policy Formation and the Push for Extended Producer Responsibility

India, still largely focused on solar expansion, is now shifting toward structured EOL planning:

·         PV waste is currently managed as general e-waste; no national guideline specifically addresses PV waste, though this is changing.

·         Recent proposals advocate for an EPR model, with manufacturers responsible for EOL take-back, transport, recovery, and recycling.

·         Significant opportunity exists to build regional recycling hubs and leverage international expertise to accelerate sustainable EOL management.


Global Table: Key Initiatives, Technologies, and Countries in Use of PV Lifecycle Management

Country/Region

Key Programs/Policies

Leading Companies/Initiatives

Technologies/Approaches

Regulatory Framework

European Union

WEEE Directive, EPR mandates

PV Cycle, PHOTORAMA, PILATUS

Advanced mechanical/chemical recycling, circular design

Mandatory recovery/recycling targets, producer liability

United States

SETO EOL Action Plan, State Laws

SOLARCYCLE, EnergyBin, We Recycle Solar

High-value recovery, AI/robotics, digital B2B platforms

State-led EOL policies, federal R&D funding

China

National recycling guidelines, green design mandates

Huamei Photoelectric, regional clusters

Industrial-scale recycling, green design

Ban on landfill, support for remanufacturing

Japan

Industrial waste policy, pending recycling mandates

AGC, Tokuyama, industry-university pilots

Pilot recycling plants, float glass recovery

Mandatory recycling under development

South Korea

Extended Producer Responsibility

Government/private recycling centers

Dedicated facilities, EPR funding

EPR in effect from 2023, regulatory recycling fees

Australia

Product Stewardship Act, state landfill bans

Smart Energy Council, PV Industries

National stewardship pilots, collection logistics

National scheme under development, state bans

India

EPR proposal under review

Growing recycling sector, pilot projects

Recovery hub concepts, borrowing from EU models

Informal to evolving regulatory framework

This table highlights how various geographies are aligning on circular economy strategies, but with diversity in policy, industry engagement, and technological priorities.


Innovations Shaping the Future of Solar Panel Circularity

Technology and Process Innovations

·         AI & Robotics: Automation is revolutionizing panel disassembly, material identification, and separation, enhancing efficiency, accuracy, and worker safety1516.

·         Solvent-Based and Selective Recovery Methods: Advanced solvent technologies enable targeted extraction of precious and rare metals, improving rates of silver, indium, and silicon recovery.

·         Release Encapsulants & Circular Design: New encapsulant formulations simplify end-of-life dismantling, reducing energy input and protecting yield of recovered materials, as demonstrated by the PILATUS project in Europe.

·         Mobile Recycling Units: Portable facilities bring circularity to sites of decommissioning, minimizing transport costs and opening new business models for service providers16.

·         Data-Driven Marketplaces: Integration of real-time performance data and sourcing histories enable traceability, quality assurance, and price transparency on platforms like EnergyBin and similar exchanges.

Policy and Economic Innovations

·         Circular Design Requirements: Regulatory and voluntary standards for products to be disassemblable and recyclable at EOL.

·         Material Passporting & Traceability: Implementing digital tracking of material flows through the lifecycle, enabling better resource management.

·         Public-Private Partnerships: A Growing number of partnerships between industry, academia, and government to develop, pilot, and scale best-in-class recycling and reuse facilities.

·         Value-Based Recovery and Remanufacturing: Prioritizing retrieval and reuse of highest-value materials, not simply by mass (e.g., silver, silicon).

Circular Economy in Action

·         Closed-Loop Pilots: EU programs such as PHOTORAMA aim for high-value, full-loop recovery and reinjection of rare materials (silver, indium, gallium, silicon) directly into new manufacturing streams, showcasing the potential for a self-sustaining PV ecosystem.

·         Asia-Pacific Leadership: China’s 2025 system target and fast-tracking of policy show how scale, regulation, and incentives can drive industry transformation, while Australia’s stewardship pilots might serve as a testbed for global best practice in decentralized residential solar recycling.


Challenges and Outlook

Barriers Remaining

·         Economic Viability: Recycling (especially of complex modules) is still more expensive than landfill or basic material salvage, except in regions with strict regulation or high landfill costs.

·         Logistics and Infrastructure: Markets outside the EU and the world’s most advanced economies often lack comprehensive logistics systems for collection, aggregation, and safe transport of panels.

·         Regulatory Fragmentation: Inconsistent policy adoption globally undermines economies of scale and technology development.

·         Market Demand: Markets for secondary modules, components, or recycled materials must mature to stabilize demand and incentivize innovation.

·         Quality Assurance: Standardized grading, certification, and traceability are urgently needed for reused and recycled modules to gain widespread market trust.

Opportunities and Potential

Despite these hurdles, momentum is building. The potential for the recovery of valuable and critical materials is enormous. Some estimates suggest 60-75% of silver and silicon requirements could ultimately be supplied from PV recycling streams by mid-century265. Employment growth in refurbishment, recycling, and remanufacturing is another key social benefit area.

With policy frameworks tightening, technological progress accelerating, and secondary markets expanding, the solar PV industry stands at a turning point. The successful scaling of reuse, recycling, and robust secondary markets will transform the challenge of solar waste into an economic and environmental opportunity that ensures solar energy is not just a green technology at the point of generation, but across its entire lifecycle.


Conclusion

The coming flood of used solar panels represents a defining challenge and opportunity for the clean energy era. Solutions are emerging at every level:

·         Reuse strategies, powered by efficient secondary markets, digital traceability, and rigorous refurbishment, can extend the life and value of PV resources across global markets.

·         Advanced recycling harnesses the latest in robotics, AI, chemical, and mechanical technologies to capture critical materials, reduce emissions, and deliver environmental and economic returns.

·         Circular economy frameworks-combining policy (e.g., EU’s WEEE, China’s new guidelines, Japan’s mandates, South Korea and Australia’s stewardship)-create the structure for integrating compliance, innovation, and value creation at scale.

Industry leaders, policymakers, and innovators now possess the knowledge and tools to transform EOL management from an afterthought to a competitive advantage. But to fully realize this vision, international coordination, investment in infrastructure, and the continued development of scalable, cost-effective technologies will be essential.

By embracing these approaches, the solar sector can sustain its progress toward a truly green, renewable, and circular energy future-providing not just electricity but also resource security, economic opportunity, and a legacy of responsible stewardship for generations to come.


Key Takeaway: The future of used solar panels is not destined for landfill, but for a dynamic lifecycle of reuse, high-value recycling, and circular reintegration, powered by regulatory innovation, technological advancement, and collaborative platforms linking markets worldwide. The journey to full circularity has begun, and its successful realization will be critical for the environmental and economic integrity of solar power in the 21st century and beyond.


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