Ensuring sustainability in solar and battery storage supply chain

What is the emerging key challenge before the rapidly growing solar sector?

The challenge for India’s solar sector isn’t just in scaling up production, but in scaling up responsibility. One of the most pressing concerns is the management of end-of-life solar panel waste. While there are recycling processes available, high costs of collection and complex processes required to separate and purify materials makes it prohibitive. The relatively low value of the recovered minerals also does not make it attractive.

Research indicates that by 2050, India will be among the top five producers of photovoltaic waste globally. Studies by International Renewable Energy Agency (IRENA) and the National Renewable Energy Laboratory (NREL) highlighted India’s rapidly growing solar capacity, underscoring the urgent need for effective recycling and disposal strategies.

What are the solar panel recycling options available?

The current recycling processes, particularly thermal methods, are energy-intensive and contribute to pollution, despite being quicker to implement than their chemical counterparts. Raw material extraction for both solar panels and batteries also poses significant environmental challenges. The mining and processing of these materials often result in substantial ecological footprints, raising questions about the long-term sustainability of the industry.

Current recycling processes for PV panels include thermal, chemical, and mechanical delamination, each with distinct pros and cons. Mechanical delamination is cost-effective and scalable but has low yield and poor recovery of high-value materials. Thermal delamination is more efficient but requires studies on exhaust gases that are generated during combustion of ethylene vinyl acetate based encapsulants and fluorinated back sheets. Chemical delamination offers the highest recovery potential but is difficult to scale due to the volume and disposal of chemicals. The choice of method depends on balancing efficiency, cost, and environmental impact.

What do you suggest for the sustainable growth of the solar industry while effectively addressing the critical issue of PV module waste?

Policy and regulatory frameworks that promote extended producer responsibility, recycling mandates and investment in innovation and research & development, can improve economies of scale and efficiencies to ensure a sustainable future.

Improvement strategies for PV module waste management include several key initiatives. Firstly, investing in innovative, energy-efficient recycling technologies, such as mechanical separation, can enhance environmental sustainability. Strengthening infrastructure for PV module waste management is also crucial to address the growing concern of solar panel waste. Additionally, adopting cleaner manufacturing processes plays a significant role. This involves utilizing renewable energy sources in manufacturing to reduce the carbon footprint and implementing less hazardous chemical processes to minimize environmental impact.

In addition, promoting circular economy approaches is essential. By focusing on product life extension through repair, refurbishment, and remanufacturing, and designing products for easier disassembly and recycling, the industry can reduce raw material demand and minimize waste generation. These strategies collectively ensure the sustainable growth of the solar industry while effectively addressing the critical issue of PV module waste.

Efficient and innovative raw material extraction processes for both solar panels and batteries processing of materials like silicon, lithium, and cobalt, can contribute to a circular economy, and help create a secondary minerals market for India , reducing ecological footprints and promoting sustainability.

What are the emerging practices to ensure sustainability in the industry?

Globally, several emerging practices are gaining traction to ensure sustainability in the solar industry.

In India, the inclusion of solar waste in the e-Waste Management Rules is a significant step towards responsible waste management. This legislation mandates the proper disposal and recycling of solar panels, aligning with global best practices. In addition, industry-led initiatives are making significant strides, with producer responsibility organizations like PV Cycle pioneering reverse logistics and recycling of PV panels in EMEA region in a sustainable manner. In the thin film solar PV industry, First Solar has pioneered a closed loop recycling system with yields over 90%.

These efforts are complemented by ongoing research and development aimed at improving recycling technologies and developing more sustainable manufacturing processes. For example, advancements in chemical recycling methods are being explored to reduce the energy intensity and environmental impact compared to traditional thermal methods. Furthermore, there is a growing focus on developing alternative materials for solar panels and batteries that are more abundant and less harmful to extract and process.

In the Asia Pacific region, including India, local technologies and initiatives are also making significant strides. For example, mechanical separation technology has demonstrated the potential for scalable and efficient recycling processes. The Solar Waste Action Plan (SWAP) pilot by dss+ successfully processed over 200 tonnes of solar waste through mechanical separation and achieved between 75-80% separation efficiency.

However, challenges remain in implementing these practices locally. The lack of robust regulatory frameworks and infrastructure, as well as limited awareness and investment in advanced recycling technologies, hinder widespread adoption. Developing local supply chains for recycled materials and enhancing regulatory support are crucial to overcoming these challenges and promoting sustainable practices in the region.

As these practices evolve and become more widespread, they have the potential to transform the solar industry into a more environmentally responsible and economically viable sector. By adopting and scaling these innovative solutions, the solar industry can address its current challenges and pave the way for a sustainable future.

For existing factories, how easy or difficult is the switch to sustainability? How can they transition to sustainable operations without significant changes or costs to their existing setups?

For companies with existing factories, it is essential to develop a practical transition plan. In almost all operations, opportunities for energy efficiency improvements can contribute to a savings of 5-10%. This can be achieved through a quick assessment to identify opportunities involving low or no capex expenditure. The saving from this can trigger further opportunities for improving energy and operational efficiency through capital projects.

Simultaneously, evaluating opportunities for adopting renewable sources of energy can lead companies on the path of reduced emissions and on the journey to net zero. Collaborating with universities on new technology development can also help solve potential future challenges. While the transition in India remains complex, industry experts suggest that a gradual implementation of sustainable practices can effectively manage costs and operational changes.

Energy efficiency improvements in existing operations are seen as a cost-effective first step towards sustainability. Implementing energy-saving measures, such as upgrading to energy-efficient machinery and optimizing production processes, can significantly reduce operational costs in the long term. Additionally, proper waste management and recycling processes for PV modules and batteries are crucial areas for improvement. Introducing robust recycling processes can involve setting up dedicated recycling units or partnering with specialized recycling firms.

To facilitate this transition, supportive government policies are essential. Recommendations include placing batteries in the lowest GST [goods and services tax] bracket and removing import duties on raw materials to reduce costs. Developing local supply chains for recycled materials can also decrease dependence on imports and foster a circular economy.

However, challenges remain. Upfront investment is needed for retrofitting and upgrading facilities, which can be a significant barrier. These initial costs can be offset by long-term savings from reduced energy consumption and improved efficiency. Potential disruptions during the transition can affect production schedules, but a phased approach can help manage these disruptions effectively. Prioritizing easy-to-implement changes, such as energy efficiency improvements, can provide immediate benefits and help spread costs over time.

Leveraging advanced technologies, such as smart manufacturing systems and IoT-enabled devices, can optimize resource use and improve overall operational efficiency. Educating employees about sustainable practices and providing training on new technologies and processes can facilitate a smoother transition. Engaging the workforce in sustainability initiatives can also drive innovation and improve morale.

As India continues its push towards renewable energy dominance, the solar and energy storage manufacturing sector stands at a crossroads. The industry’s ability to address these sustainability challenges will be crucial in determining its long-term success and environmental impact. With continued research, development, and supportive policies, India has the potential to become a global leader in sustainable solar and energy storage manufacturing.

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