SOPHIA

With the rapid rollout of solar energy, which is at the forefront of efforts to reduce carbon emissions, there is a growing need for solutions to increase the circularity of PV panels, bridging the gap between the manufacturing and end-of-life processes, and keeping critical and valuable materials in use for as long as possible.

The SOPHIA project - Implementation of Advanced Digital Solutions to increase the circularity of PV panels throughout the full value chain – is an EU-funded Horizon Europe project that aims to implement Advanced Digital Solutions in end-of-life solar panels, involving the full value chain in order to increase their current reuse, repair and recycling rates.

For the evaluation of their State-of-Health (SoH), a prototype will be developed for a fast evaluation of its efficiency, black areas and main damages. Solar panels with remaining efficiency >80% will be repaired using a robot-assisted equipment and high-performance dielectric varnish. The non-reparable ones will be recycled using innovative technologies to maximize the separation of their main components (glass, silicon & metals and plastics). For the case of the glass fraction an in-line antimony quantification system will be implemented to maximize their fraction and valorization.

The following innovations are being targeted:

• State-of-Health Assessment: A prototype will be developed for rapid evaluation of solar panels, assessing efficiency, identifying black areas (damaged regions), and determining main damages.
• Repair and Recycling: Solar panels with over 80% remaining efficiency will be repaired using robot-assisted technology and high-performance dielectric varnish. Non-repairable panels will be processed with innovative recycling methods to maximize the separation and recovery of their primary components: glass, silicon, metals, and plastics.
• Enhanced Glass Valorization: An inline antimony quantification system will be implemented to optimize the valorization of the glass fraction.
• Eco-Designed Panels: To ensure long-term circularity, a new eco-friendly solar panel will be developed that features easy dismantling using tailor-made debonding on-demand adhesives.
• Digital Product Passport (DPP): A digital platform will be established to implement the DPP for both new and repaired solar panels, facilitating the collection of information to trace existing panels that lack a DPP. This traceability will allow for improved identification of panels and components, enhancing their potential for repair or recycling and increasing the quality of secondary raw materials.

The role of Fraunhofer IWKS: 

We are leading PV panel pretreatment for recycling (i.e. mechanical shredding and sorting of fractions). We will use common and innovative fragmentation techniques and solutions like our Electrohydraulic Fragmentation, 4-shaft-shredder and a sorting line including eddy current and magnetic separation, a multi-sensor system with CCD line cameras, NIR and the possibility for machine learning.

By the end of the project, we want to have developed a pilot line for shredding and sorting PV modules that can process 200 kg/h. The annex should be able to produce three fractions (pure glass fraction, silicon with low glass content and plastic).

As a result of the research and development work carried out in this project, the following effects are expected:

• Market Integration: The repaired and eco-designed panels, along with upcycled fractions from end-of-life PV panels, will be available for sale on a specialized marketplace, with each product supported by a DPP system.
• Expected Impact: By advancing innovative solutions to boost the circularity of PV panels, the SOPHIA project will contribute to a more circular, innovative, and competitive Europe, paving the way for sustainable practices in the solar energy sector.

Through the development of innovative solutions to boost PV panels circularity, SOPHIA will contribute to fostering a more circular, innovative and competitive Europe.