Early backsheet removal cuts particulate emissions in thermal PV recycling

Researchers in Italy have reported preliminary findings on selective backsheet removal for crystalline silicon PV modules, according to pv magazine. The study indicates that particulate emissions decreased from 69.0 mg/Nm³ to 44.1 mg/Nm³ during the recycling process. The results suggest that this method helps keep titanium dioxide out of recovered glass, silicon, and metal fractions.

The data comes from tests conducted by the Italian research team, though the findings are not yet peer-reviewed. While the reduction in particulates is notable, the researchers emphasize that correlation does not imply causation. The study provides an initial look at how early backsheet removal might influence emission levels, but further validation is needed to confirm these estimates. The team notes that the approach could offer insights into managing specific contaminants in thermal PV recycling streams.

Process and Emissions

The technical foundation for this selective backsheet removal approach rests on intellectual property developed by ENEA and Beta-Tech, who patented the specific process. This method integrates with a broader recycling workflow where 9-Tech developed the pilot-scale thermomechanical recycling process. For developers and investors, understanding the provenance of such technology is essential, as proprietary methods can dictate operational efficiency and long-term viability in thermal PV recycling streams. The integration of these distinct technical contributions suggests a collaborative effort to refine how modules are disassembled and processed before material recovery begins.

Operational impacts of this early removal step extend beyond particulate control to energy inputs. Tests indicated that external propane demand increased by roughly 20% during the process. Propane is typically used as a fuel source in thermal stages, where high temperatures are required to break down organic materials or facilitate separation. An increase in fuel consumption represents a direct operational cost factor that must be weighed against the benefits of cleaner material streams. Conversely, electricity consumption remained unchanged during these tests. This stability in power usage is significant because thermal recycling plants often rely heavily on electrical energy for mechanical grinding and sorting. Keeping electricity demand flat while adjusting fuel inputs suggests that the backsheet removal step does not place additional strain on the electrical grid or local power infrastructure. For facility operators, this balance between fuel and power usage helps maintain predictable energy costs, which is a critical consideration when scaling pilot projects toward commercial deployment.

Material Recovery and Contamination

The physical scale and specific inputs of this pilot operation define the practical limits of the current findings. Key parameters from the study include:

• The specific module model tested was the Trina Solar TSM-230PC05.
• The pilot plant processed material at a capacity of 30 kg per hour.
• 9-Tech reported an 87% material recovery rate for the process in 2024.

These specifications place the research firmly in the pilot stage, where throughput is measured in kilograms rather than the tons typical of commercial facilities. For investors evaluating thermal recycling ventures, the recovery rate is a critical metric that directly influences the economic viability of the output. An 87% recovery figure suggests that the majority of the module’s mass is successfully captured, minimizing waste sent to landfill. However, the specific use of Trina Solar TSM-230PC05 panels means the results are tied to a particular construction standard. While this model represents a common crystalline silicon design, variations in module architecture across different manufacturers can alter how materials separate during thermal stages.

The 30 kg per hour capacity highlights the gap between laboratory validation and industrial deployment. Scaling such a process requires ensuring that the high recovery rates observed at low volumes remain consistent as throughput increases. Contamination risks, such as titanium dioxide migrating into glass fractions, must be managed rigorously at this scale to ensure the recycled materials meet market standards. For developers, understanding that these results are specific to this pilot setup and module type is essential before extrapolating performance to larger, multi-vendor recycling streams. The balance between high recovery rates and strict contamination control remains the central challenge in transitioning from pilot data to commercial operations.

Project Context and Partners

The technical work described here does not exist in isolation; it operates within the structured framework of the EVERPV project, funded under the European Union’s Horizon Europe program. For stakeholders familiar with EU research funding, this context is significant because Horizon Europe typically supports large-scale, collaborative initiatives designed to bridge the gap between academic discovery and industrial application. Such projects usually bring together universities, research institutes, and private companies to share risks and resources, ensuring that pilot-scale innovations receive the rigorous testing required before commercial rollout. Participation in an EVERPV consortium signals that the backsheet removal method is part of a coordinated effort to address end-of-life PV waste, rather than a standalone experiment. This alignment with broader European strategic goals can influence how investors and policymakers view the long-term viability of the technology, as it benefits from the institutional support and peer recognition associated with major EU research grants.

The physical location of the pilot facility further grounds the study in a specific industrial reality. The 9-Tech pilot plant is situated in Porto Marghera, a neighborhood in Venice historically known for heavy industry. While the area has undergone significant environmental remediation and economic transition in recent years, it remains a recognizable hub for manufacturing and chemical processing in northern Italy. For facility operators, locating a pilot line in an established industrial zone offers practical advantages, including access to specialized labor, supply chains for materials like propane, and existing infrastructure for waste management. This geographic placement suggests that the team is testing the process in conditions that reflect real-world industrial constraints, rather than in a controlled laboratory environment. Understanding this setting helps contextualize the preliminary findings, as the operational dynamics of a plant in Porto Marghera may differ from those in less industrialized regions, potentially affecting how the technology scales across different European markets.

What to watch

The immediate next milestone for this technology is the transition from pilot validation to full industrial deployment. 9-Tech is currently developing an industrial-scale plant in partnership with Veritas. This move marks a critical shift from the low-throughput testing environment described earlier to a facility designed for commercial volumes. For investors and operators, the success of this new plant will hinge on whether the high material recovery rates observed at the pilot stage hold up under continuous, large-scale operation.

Readers should look closely at how the backsheet removal step performs when integrated into a larger production line. While the pilot data suggested stable electricity usage, industrial plants face different logistical and mechanical demands. The partnership with Veritas suggests a focus on operationalizing the process, but the specific engineering challenges of scaling will become apparent as construction and commissioning progress.

The durability of the contamination controls remains an open question. As throughput increases, maintaining the purity of the glass and metal streams becomes more difficult. Watch for announcements regarding the final configuration of the Veritas-9-Tech facility and any independent audits of its emissions and recovery performance. These details will determine if the method can be replicated across diverse module types in the broader European market.