Modelling the fabrication process to recycle discarded solar panel into composite and microstructure characterisation

Abstract

The current global shift towards renewable energy has led to increased use of solar panels. However, there is a problem with this shift, that is, accumulation of end-of-life solar panels, which are disposed of after 25–30 years. The solar panel consists of an aluminium frame, a photovoltaic layer, a glass sheet, a plastic backing sheet, and a junction box. The components, aluminium frame and glass sheet at the front, have high recyclable value, but the segregation of these components from the solar panel sandwich is a critical task. Even after segregation, the components remain severely contaminated due to weathering. To address this issue, a recycling process is modelled that involves chemical leaching with an ethanol blend and fabrication of a metal matrix composite from segregated components via stir casting. The process is statistically optimised using Response Surface Methodology (RSM), which yielded an optimal casting condition with an agitation speed of 259 r/min, a casting temperature of 850.60°C, and a 11.60 wt% reinforcement addition. This resulted in samples with a strength of 329.52 MPa and a hardness of 162.23 HV. The chemical composition of the samples was investigated using Energy Dispersive X-ray Spectroscopy (EDS), the phase distribution was examined using X-ray Diffraction (XRD), and the reinforcement distribution was examined using Scanning Electron Microscopy (SEM).