As global attention to climate change intensifies and carbon neutrality strategies advance, solar energy has become a cornerstone of the global clean energy agenda. As a clean and renewable energy source, it plays a key role in the energy transition.
- According to data published by the American Chemical Society (ACS Publications), global photovoltaic (PV) installed capacity increased from 4 GW in 2000to 760 GW in 2020, accounting for nearly 4% of global electricity generation. (Bibliography)
- According to data from Our World in Databased on statistics from IRENA, global cumulative installed solar capacity reached 1,422 GW by the end of 2023. (Bibliography)
- The International Energy Agency’s Photovoltaic Power Systems Programme (IEA-PVPS)reported that, by the end of 2024, global cumulative solar capacity had reached approximately 2,246 GW (2.25 TW). (Bibliography)
- Projections from Elsevier (ScienceDirect)estimate that global installed solar capacity will exceed 5,000 GW by 2050. (Bibliography)
With an average operational lifespan of 20 – 30 years, early PV systems installed in the 2000s are expected to enter large-scale decommissioning between 2025–2035. By 2050, global PV waste may exceed 78 million metric tons, raising major challenges in resource recovery, environmental management, and policy regulation. (Bibliography)
Challenges & Environmental Risks in Solar Panel Recycling
Recycling Challenges
- Complex structure: Photovoltaic panels consist of aluminum alloy frames, tempered glass, silicon-based solar cells, EVA encapsulants, polymer back sheets, and trace amounts of precious metals (e.g., silver), making material separation technically difficult.
- Neglected high-value materials: Most current recycling processes recover only aluminum and glass—accounting for roughly 80% of panel mass—while valuable materials such as silver, copper, and silicon are often discarded or lost during processing.
- Tightly bonded encapsulants: EVA layers are chemically cross-linked and difficult to delaminate, complicating disassembly and increasing processing costs.
- Toxic components: Legacy modules may contain hazardous substances such as lead and cadmium, which pose contamination risks to soil and water if improperly handled.
- Low manual efficiency: Manual dismantling is labor-intensive, costly, and unsuitable for large-scale operations.
Low Recycling Rates & Environmental Risks
- In the United States, only around 10%of decommissioned PV panels are recycled; the majority are landfilled or incinerated.
- Leaching of heavy metalsfrom untreated panels can result in long-term ecological damage and pose risks to human health.
Technical & Economic Bottlenecks in PV Module Recycling
| Method | Advantages | Limitations |
| Mechanical | Low cost, simple operation | Incomplete separation, low material purity |
| Thermal (Pyrolysis) | Effective encapsulant removal | High energy consumption, equipment-intensive |
| Chemical | High recovery rate, good material purity | Expensive, difficult pollution control |
View methods
Process Challenges & Long-Term Barriers
| Category | Current Issues | Ongoing Challenges |
| Separation Process | Complex material composition; difficult to disassemble | Still dependent on manual or costly precision sorting |
| Thermal Efficiency | Traditional equipment wears out quickly | Ineffective for high-volume, high-hardness modules |
| Cost Management | High integrated costs (dismantling, transport, sorting) | Low profit margin; weak market-driven incentives |
Research indicates that recycling a crystalline silicon PV module costs approximately $15–45, while landfill disposal costs just $1–5. The lack of economic incentives has become one of the key barriers to the development of a global PV recycling system. (Bibliography)
Shredding Recycling Solution: The Central Role of Double shaft shredder
During the pre-treatment stage, twin-shaft shredders serve as a critical technology to enable efficient material recovery.
- High torque & low speed: Minimizes dust generation and reduces wear on equipment.
- Versatile adaptability: Capable of shredding multilayer composite structures such as glass, metal frames, and polymer films.
- Uniform output size: Facilitates downstream separation processes including magnetic, air, and eddy current sorting.
Core Equipment Configuration
| Component | Function Description |
| Double shaft shredder | Primary shredding with particle size width of 40–60 mm |
| Intelligent Control System (PLC) | Auto-reverse/Anti-jam mechanism/Overheat |
| Wear-resistant alloy blades | D2 alloy steel or custom hard alloy |
Optional Auxiliary Equipment (to optimize recovery efficiency)
| Auxiliary Equipment | Function |
| Crusher | Further reduces material to target size (10–50 mm) |
| Magnetic Separator | Extracts ferromagnetic metals (e.g., steel frames, screws) |
| Eddy Current Separator | Sorts non-ferrous metals (e.g., aluminum, copper, silver) |
| Conveyor Belt | PVC or metal chain type; auto-feeding and discharge speed control |
| Dust Collection System | Prevents airborne pollution and secondary environmental risks |
| Vibrating Screen + Air Classifier | Separates lightweight materials (plastics, EVA fragments) from glass |
Strategic Pillars for Building a Global PV Recycling System: Technology, Policy, & Collaboration
As the global solar sector approaches a wave of PV module decommissioning, the world faces pressing environmental and resource challenges. Serving as a critical front-end solution, Double shaft shredder enhance processing efficiency and enable the recovery of high-value materials. Countries should strengthen policy frameworks, invest in recycling technology, and build robust collection and recovery systems to realize the full circular potential of green energy.
Additional notes:
Recyclable Materials in PV Modules
Material Component |
Weight Share |
Recyclable Value |
Application / Notes |
| Glass | ~70% | Moderate | Can be recycled into secondary glass or building materials |
| Aluminum Frame | ~10% | High | Remelted for reuse; high economic value |
| Silicon Cells | ~5–6% | Relatively High | High-purity silicon can be purified and reused |
| Silver (Electrodes) | ~0.05% | Very High | High-value metal for resale or remanufacturing |
| Copper (Wires) | ~1% | High | Recoverable via smelting |
| EVA/Backsheet Plastics | ~10% | Limited | Difficult to reuse; thermal recovery or chemical cracking |
| Lead/Cadmium/Chromium/Nickel | ~<0.1% | Hazardous | Non-recyclable; must be contained to prevent leakage |
Diverse Revenue Pathways in PV Recycling
| Revenue Source | Description |
| Material Sales Revenue | Key: aluminum frames (~60–70% of value); secondary: copper/silver |
| Government Subsidies | Carbon credits or financial incentives in many countries |
| Corporate ESG Branding | Participation enhances manufacturers’ ESG ratings and green credentials |
| Material Circularity | Recycled materials can be reintroduced into new PV production (closed-loop) |