Hybrid delamination of silver contacts from c-Si solar cells: a low environmental impact recycling approach

As deployment of photovoltaic (PV) systems intensify amidst the shift towards renewable energy sources, the imperative to minimise their environmental footprint across the full life cycle has become increasingly critical. Here, we introduce a novel Hybrid process for recovering silver (Ag) from monocrystalline silicon (Si) PV cells that achieves a 93 % Ag recovery yield. By selectively removing aluminium (Al) with sodium hydroxide (NaOH) and delaminating busbars using iron chloride (FeCl₃), pure Ag is recovered by mechanical filtration, minimising purification needs. Life Cycle Assessment (LCA) indicated reduced climate change and human toxicity burdens compared to Conventional or Brine-based leaching, attributed to lower reagent consumption and fewer purification steps. Techno-economic analysis (TEA) highlighted cost challenges, indicating net losses due to high waste disposal fees and chemical usage, despite substantial revenue from recovered Ag. These findings highlight the critical role of high-value recycling and supportive policies in advancing a sustainable PV industry.