As the first generation of solar panels reaches the end of its lifespan, efficient recycling becomes increasingly important. Dutch research organisation TNO has developed a laser-based recycling technology that could improve how valuable materials are recovered from photovoltaic (PV) panels. The method recovers up to 99% of the silver inside solar panels while using far less energy than current recycling techniques.

Why Solar Panels Are Difficult to Recycle

Manufacturers design solar panels to last at least 25 years. The panels must resist heat, moisture, cold and mechanical stress. To achieve this, producers strongly bond together glass, silicon cells and protective encapsulating layers. However, this durable construction creates major recycling challenges. Current recycling methods often crush panels or heat them to very high temperatures. These processes damage valuable materials and consume large amounts of energy. As a result, recyclers rarely recover silver and high-purity silicon efficiently.

Recycling With Laser Technology

TNO’s new method separates solar panel layers in a cleaner and more precise way. The technology uses a focused laser beam to generate local heat inside the active layer of the panel. This heat weakens the adhesive bond between the solar cells and encapsulating materials.

The process allows recyclers to separate the layers without chemicals or extreme heating. As a result, the glass remains intact and the solar cells contain very little adhesive residue after treatment. The laser process also uses significantly less energy. TNO reports that the system requires less than 1 kWh per module. Conventional pyrolysis techniques typically use around 25 kWh per module.

Recovering Silver and Silicon

The technology could support a more circular solar industry by recovering critical raw materials at high quality. In 2024, manufacturers used approximately 24% of the world’s mined silver in solar panels. Demand for the metal continues to grow rapidly.

TNO estimates that its recycling method can recover up to 99% of this silver. The process also preserves high-purity silicon, which companies could reuse in batteries or new solar panels. In addition, the clean separation improves the recycling potential of glass and polymer materials.

Scaling Up for Industrial Use

TNO has worked on the technology for the past three years. Researchers have already tested the process successfully on several common solar panel types. The team continues to optimise the system and study how different laser configurations affect the adhesive layers.

The project has now moved beyond the laboratory stage. TNO currently works with machine manufacturers, solar panel producers, recycling companies and policymakers to prepare the technology for industrial-scale recycling.

According to TNO research lead Mirjam Theelen, Europe will soon face growing volumes of discarded solar panels. She believes the technology could turn this waste stream into an important source of valuable raw materials while supporting a more independent and circular solar energy sector.

Source: TNO / Duurzaam Ondernemen
Photo: Bru-nO