End-of-life management of solar photovoltaic (PV) systems is fast emerging as a challenge and a strategic priority for manufacturing industries worldwide. Especially, aluminium circularity is becoming a focal point considering the metal accounts for more than about 85 per cent of PV component materials like frames and mounting structures. Truth to be told, solar waste is a growing concern now with the rapid rise in PV installations globally. In 2024, global installed capacity exceeded 2.2 TW, with nearly 600 GW added in a single year. Going by the International Renewable Energy Agency’s (IRENA) estimation, around 1.7-8 million tons of waste are likely to be generated from PV modules by 2030, and that by 2050, is expected to soar to between 60 and 78 million tons, a substantial share of which will consist of aluminium scrap.

Present usage and projection of aluminium usage in solar PVs

Aluminium is an integrated material of solar panels in both distributed and utility scale systems. 6-series aluminium primarily serves as a structural material in module frames and racking systems. In 2024, about 8 million tons of aluminium was used in the manufacture of PV systems, of which 4 million tons was used only in China’s domestic PV capacity. By 2030, in Europe alone, an additional 4 to 10 million tons of aluminium would be required for photovoltaic structures as there is a projection of twofold increase in solar PV capacity to more than 750 GW. On average, manufacturing 1 MW of PV capacity requires 21 tons of aluminium, according to Wood Mackenzie data. In concentrating solar power (CSP) systems, aluminium intensity is even higher than twice that amount, at approximately 47 kg per kW.

Hindrance and solutions to aluminium waste from PVs

 So, if such large volume of aluminium goes into PV structures, then it is no longer a choice but imperative to scale up the recycle and reuse of aluminium waste generated from solar photovoltaic. Rethink, reuse, and recycle must become foundational principles for managing the growing aluminium scrap stream from PV systems. While there is a rapid growth in PV installation in Europe, the government has done a fair job through mandatory collection and recycling targets under the WEEE (Waste from Electrical and Electronic Equipment) Directive, achieving over 80 per cent of PV recovery rates.

However, policy design is not sufficient. Upstream design and material selection remain critical challenges to achieving aluminium circularity in solar PV. Often due to cost, PV manufacturers choose alternative materials to aluminium such as polycarbonate and composites, but these materials pose end-of-life challenges as they are difficult to recycle. Conversely, aluminium is recyclable but upstream players in the solar PV industry are majorly driven by material suitability, aesthetics, and cost requirements of customers, with limited end-of-life considerations.

Concerns around recycled aluminium quality further complicate adoption. PV manufacturers worry about residual trace element comprising alloy strength and corrosion resistance that could create liability risk. However, according to the International Aluminium Institute, these concerns can be mitigated through improved supply chain transparency, certification standards, and contractual protections. IAI further highlights that certain aluminium components, particularly distributed racking systems, often outlast PV modules and offer strong potential for reuse in secondary applications. So, scaling the reuse of end-of-life aluminium components in PV systems would require supply chain standardization and certification infrastructure, which still remains nascent globally at this moment.

Policy maturity varies widely, but the opportunity for product stewardship is strong and clear. In this case, Europe and China lead the way, where there are strict regulations for PV recycling. Most of the other markets, such as Australia, Canada, India, and the United States, remain fragmented. Europe’s mandatory extended producer responsibility (EPR) regimes together with landfill taxes and bans have increased aluminium recovery rates by over 80 per cent. China, on the other hand, despite lacking formal EPR regulation, has still attained an industry-scale recycling rate of 34-75 per cent. In the US, the recycling rate of PV aluminium is less than 10 per cent.

Collaboration plays a key role here

To unlock aluminium circularity in the solar PV sector, responsibility must be shared across the value chain, with coordinated action from governments, industry stakeholders, and recyclers.

The Government must -

• Strengthen policy and market signals through enforced product stewardship (e.g. EPR schemes for PV modules)
• Support recycling and reuse infrastructure with dedicated grants or low-interest finance
• Enable reuse pathways with national standards for second-life PV and racking with regulatory assurance for exports

Project developers and installers must –

• Establish end-of-life offtake arrangements with recyclers
• Work with certified refurbishers to test, grade and document removed modules and racking for reuse

Disassemblers and PV recyclers must –

• Reduce contamination and module damage during disassembly and develop co-located hubs with scrap traders to leverage existing infrastructure
• Work with standards bodies, governments and refurbishers to certify recovered materials and PV modules for reuse

Scrap metal traders must –

• Create dedicated streams and invest in sorting to verify alloy composition and improve PV aluminium feedstock quality
• Build direct relationships with solar PV supplying casthouses and extruders to align specifications and secure offtake

The twin advantage of aluminium recycling in solar PV

Material-wise, glass and aluminium make up nearly 90 per cent of solar photovoltaic structure, while the remaining 10 per cent is consisted of silicon, polymers, and traces of precious metals. PV frames typically use 6063-T5/T6 aluminium billets, while racking systems rely on alloys such as 6063-T5/T6, 6061-T6, and 6005-T5.

Despite structural challenges, the opportunity for aluminium circularity is significant. Notably, up to 30 per cent of decommissioned PV panels are removed prematurely due to degradation or early failure, creating an early and growing scrap stream. At present, most PV systems rely heavily on primary aluminium sourced through linear supply chains. Continued dependence on primary aluminium poses both supply risks and environmental costs, given that primary aluminium production carried an average emissions intensity of 14.8 tCO₂e per ton as of 2023.

In contrast, recycled aluminium emits just 0.5–2 tCO₂e per ton, compared with 12–17 tCO₂e for primary production. As global PV installations accelerate, enhancing aluminium circularity is not merely an environmental imperative—it is a strategic necessity to ensure material security, cost stability, and the long-term sustainability of the solar energy transition.

Source：AL Circle