Automation of PV Panel Recycling

Abstract

The rapid growth of photovoltaic (PV) deployment is accelerating the need for scalable, automated end-of-life processing. This thesis develops and evaluates an integrated recycling pathway that targets two major bottlenecks: automated de-framing of PV modules and post-comminution electrostatic separation. A compact de-framing machine was designed around a linear-rail stage and a constrained-DOF lift-and-turn architecture to push off bonded aluminum frames while maintaining panel support. The end-effector includes paired pushing arms and a blade set for junction-box removal; a weighted trade study favored a pneumatic actuator for simplicity, response, and maintainability. A roll-and-corona electrostatic separator was also designed (Ø340 mm roller; corona at 250 mm, 70°; static field electrode at 260 mm, 45°) with adjustable splitters, integrated brush cleaning, and an industrial footprint of 1260 × 1255 × 955 mm.
Finite-element analysis (ANSYS) modeled the frame–laminate interaction using two failure representations for the silicone bead: (i) contact debonding via a cohesive zone interface and (ii) bulk cohesive rupture with hyperelastic (Mooney–Rivlin) silicone. The hyperelastic fit used C10 = 0.086 MPa and C01 = 0.011 MPa, with near incompressibility (D1 ≪ 1). Peak reaction forces distinguished the governing de-framing mode: cohesive rupture required 11.7 kN at the rupture onset (4 mm-imposed displacement), whereas interface debonding demanded 17 kN, indicating de-framing will be limited by silicone rupture under the modeled conditions (lower force governs).
A preliminary technoeconomic analysis was performed for a single-shift plant sized to 900 t/yr throughput (8 h/day, 250 days/yr), establishing system boundaries, recovery assumptions, and market pricing for recycled-grade outputs. Total capital expenditure (equipment, land, building, utilities, contingency, installation) is estimated at 1.075 M USD, with annual OPEX of 0.613 M USD (labor 0.524 M, electricity 0.052 M, consumables 0.036 M). Annual revenue from recovered materials is 1.284 M USD; adding monetized CO₂-equivalent avoidance at 1,818 t/yr (8.5 USD/t) yields 1.299 M USD gross. The first-year net return is −0.388 M USD, implying a breakeven fee of 8.62 USD per panel under baseline assumptions; sensitivity to commodity prices and solvent energy demand is discussed. Collectively, the results demonstrate a feasible automation concept for de-framing and sorting, establish a defensible de-framing design load (11.7 kN), and outline an economic pathway that becomes competitive with modest policy support or improved energy integration, while delivering measurable environmental benefits via material recovery and avoided emissions.

Date of Award	2025
Original language	American English
Supervisor	Hamad Karki (Supervisor)