Rapid growth in global photovoltaic (PV) deployment is creating an expanding stream of end-of-life crystalline‑silicon modules, yet advanced recycling routes remain difficult to evaluate because high-resolution inventories that resolve internal unit operations are still limited. Here, we assess the Advanced PhotoLife (APL) solvent-based recycling process by integrating process simulation, material flow analysis (MFA), life cycle assessment (LCA), and life cycle costing (LCC) for the treatment of 1000 kg of retired modules in China. The treatment stage emits 829 kg CO2-eq and consumes 6168 MJ, with physical-chemical classification contributing 71.0% of global warming potential and 64.6% of cumulative energy demand, mainly due to cyclohexane-related upstream burdens, direct emissions from the thermal oxidation of ethylene vinyl acetate flakes and residual cyclohexane, and electricity use. After system expansion, the process achieves net reductions of −2362 kg CO2-eq and −30,983 MJ, and all midpoint impact categories remain net negative under the adopted substitution assumptions. The baseline net economic profit reaches 1734 CNY/t, while the net environmental profit reaches 7529 CNY/t. Sensitivity analysis identifies energy recovery, solvent-loop closure, silver recovery efficiency, transport distance, and electricity-mix evolution as the principal performance levers. These results indicate that robust assessment of advanced PV recycling should integrate mass recovery, product quality, credible substitution, solvent containment, energy integration, and regionally coordinated recycling networks.
From process simulation to circular value: environmental-economic assessment of advanced recycling for end-of-life photovoltaics
Junzhang Wu;
2026
Abstract
Rapid growth in global photovoltaic (PV) deployment is creating an expanding stream of end-of-life crystalline‑silicon modules, yet advanced recycling routes remain difficult to evaluate because high-resolution inventories that resolve internal unit operations are still limited. Here, we assess the Advanced PhotoLife (APL) solvent-based recycling process by integrating process simulation, material flow analysis (MFA), life cycle assessment (LCA), and life cycle costing (LCC) for the treatment of 1000 kg of retired modules in China. The treatment stage emits 829 kg CO2-eq and consumes 6168 MJ, with physical-chemical classification contributing 71.0% of global warming potential and 64.6% of cumulative energy demand, mainly due to cyclohexane-related upstream burdens, direct emissions from the thermal oxidation of ethylene vinyl acetate flakes and residual cyclohexane, and electricity use. After system expansion, the process achieves net reductions of −2362 kg CO2-eq and −30,983 MJ, and all midpoint impact categories remain net negative under the adopted substitution assumptions. The baseline net economic profit reaches 1734 CNY/t, while the net environmental profit reaches 7529 CNY/t. Sensitivity analysis identifies energy recovery, solvent-loop closure, silver recovery efficiency, transport distance, and electricity-mix evolution as the principal performance levers. These results indicate that robust assessment of advanced PV recycling should integrate mass recovery, product quality, credible substitution, solvent containment, energy integration, and regionally coordinated recycling networks.
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