The EU has set out to reduce negative impacts from electricity generation on the environment, human health and towards our dependence on fossil fuels. As the fastest growing renewable source of electricity, photovoltaics plays an important role in the energy transition. The manufacturing of photovoltaic modules requires materials classified as critical, making them prone to supply disruptions. Although these materials are essential to the EU economy, they are not sufficiently recovered at the end of a photovoltaic module’s life. An alternative intermediate solution could be to extend the lifespan of existing modules, to slow down demand for these materials in the future.
The aim of this study was to analyse the theoretical options and practical examples of product life extension strategies for photovoltaics. The R-Ladder was used as a guiding framework, which provided examples of life extension strategies. These include Reuse, Repair, Refurbishment, Remanufacture and Repurpose. Aspects for each of these strategies were analysed to find potential benefits and challenges related to four aspects: economics, environment, energy, and materials.
The approach of this study includes a literature review to identify the life extension strategies discussed specifically for photovoltaics in the context of the circular economy. This was followed by a multi-case study on practical applications of Reuse, Repair and Repurposing of photovoltaic modules. Findings from literature and the case study were further supplemented with the insights from six experts. These experts had diverse backgrounds in research, manufacturing, and procurement to offer a variety of insights and perspectives on life extension strategies for photovoltaics. Finally, two scenarios were created for possible life extension pathways for used photovoltaic modules to illustrate the potential impacts compared to a commonplace premature replacement scenario.
Economics and module performance are key factors in decision-making and acquisition of a photovoltaic system. Reuse offers a compelling alternative to current recycling capabilities but offers no sufficient business case. Repair may extend a module’s lifespan to continue the generation of renewable electricity but is only possible in cases of minor damage for which replacement parts are available. Refurbishment could restore more severe damage but is limited by economies of scale and the technical difficulties resulting from current photovoltaic module design. Remanufacturing has the potential to restore a solar cell’s original performance or even upgrade it using newer processing methods but suffers from the same design limitations as Refurbishment. Repurposing used modules can offer a pathway to extract the remaining capacity if it is implemented in a context where generation density is of no concern. Combined, these strategies could buy time to address the resource challenges amplified by the energy transition.