Economics and Environmental Impacts of Photovoltaic Panel Recycling in Germany

The rapid expansion of solar photovoltaic (PV) deployment has led to increasing concerns regarding end-of-life module management and the sustainability of material supply chains, where waste volumes are projected to reach 3.3–5.6 million tons by 2045. This study evaluates the environmental and economic impact of advanced photovoltaic recycling in Germany, focusing on high-value material recovery from crystalline silicon modules. A Full Recovery of End-of-Life Photovoltaics (FRELP) pathway is developed, integrating light-pulse delamination and molten salt etching, and a comparative life cycle assessment and economic assessment framework is applied. The results indicate that advanced recycling achieves high recovery rates for silicon, silver, aluminum, copper and low-iron glass, yielding around €1174.88 per ton of panels recycled. Economic analysis shows that manufacturing PV modules from recycled materials reduces costs by approximately 60–77% compared to virgin material production, mainly due to avoided energy-intensive upstream processes. From an environmental perspective, the recycling-based pathway yields net benefits across impact categories, as avoided impacts from primary material extraction outweigh additional burdens associated with recycling. Overall, PV recycling in Europe is shown to be environmentally and economically favorable; however, technological maturity and policy constraints remain key barriers to large-scale implementation and a holistic overall recycling process, indicating the need for targeted policy support.