Bayan licenses Australian solar cell recycling technology

Bayan Mining and Minerals Ltd (BMM) has announced that it has reached an agreement to exclusively license IP from Macquarie University for solar cell recycling technology. Macquarie University’s Microwave Joule Heating is a microwave-based technology to soften the EVA encapsulant in solar panels, enabling easy delamination and potential recovery of valuable materials at room temperature. This approach avoids the need for extreme heat (1400°C) typically required for separating materials like glass and silicon as well as the use of costly hazardous chemicals.

Delamination enables selective separation of materials without the need for mechanical crushing, whereas traditional crushing methods often result in cross-contaminated material and lower recovery rates.

By 2035, Australia is expected to accumulate 1 million tonnes of solar panel waste worth over $1 billion, while the global CIGS (copper, indium, gallium, selenide) solar cell market is projected to grow to US$12.23 billion by 2032.

The team from the School of Engineering at Macquarie University, led by Dr Binesh Puthen Veettil, have developed a new microwave technology that will solve the challenge of electronic waste from end-of-life solar panels. The current solar panel recycling process is technically challenging with only an estimated 15% of solar panels making it to a recycling facility, and the remainder going straight to landfill once they have reached their 20- to 25-year life span. In the rare instance they are recycled, the solar panels, in the traditional method, are crushed and heated at approximately 1400°C before being washed in harsh chemicals to remove the plastics.

The research of Veettil, in collaboration with the School of Photovoltaics at UNSW, the Australian Centre for Advanced Photovoltaics and further supported by the Australian Government through the Australian Renewable Energy Agency, highlights the immense need and impact this technology will bring.

In this new method, the microwave energy is used to selectively heat the materials within a solar panel. In this process, the silicon cells and other microwave-absorbing components rapidly heat up, while surrounding materials remain relatively cool. This targeted heating causes the plastic encapsulant, ethylene vinyl acetate (EVA), which holds the panel layers together to soften and degrade.

As the EVA loses adhesion, the glass, silicon and metal components can be easily separated through mechanical peeling rather than through extensive processing. This method eliminates the need for traditional high-temperature baking or energy-intensive chemical treatments such as nitric acid (HNO₃), sulfuric acid (H₂SO₄) and hydrogen fluoride (HF), making delamination more efficient and environmentally friendly. This whole process can be undertaken at room temperature and de-risks the process from potential contamination concerns.

Microwave recycling has a low overall environmental impact compared to traditional recycling methods. One of its key advantages is major energy savings, which significantly reduces the carbon footprint of the process. By eliminating the need for high-temperature furnaces and chemical treatments, this method minimises greenhouse gas emissions and completely removes the risk of toxic chemical waste streams.

By using microwave-based separation, solar panels can be recycled more effectively, preserving valuable materials such as high-purity silicon, silver and other critical metals for reuse. This innovation represents a breakthrough in sustainable solar panel recycling, reducing energy consumption while improving material recovery rates.

“I’m thrilled to see this technology being adopted to tackle the growing challenge of solar panel recycling on a global scale,” Veettil said. “This innovation not only provides a sustainable solution to managing end-of-life photovoltaic modules but also lays the groundwork for broader applications in critical mineral recovery. As we refine and expand this approach, I look forward to seeing it evolve into a transformative tool that supports the semiconductor industry and strengthens global supply chains for high-value materials.”

By 2045, Australia is potentially set to dispose of 34.6 GW of serviceable panels that will require recycling or repurposing, which is equivalent to the total installed solar capacity in Australia as of August 2024.

The demand for critical minerals continues to surge as the world accelerates its transition to clean energy. Solar panels consist of 95% recyclable materials, including silver, aluminium, silicon, copper, indium and gallium, all of which are essential to global clean energy supply chains. Rare metals, such as gallium, are essential for solar fuel cells, semiconductor chips and other high-tech applications, making their recovery from e-waste materials a strategic priority.

BMM says it will seek to further develop the proprietary microwave Joule heating technology while actively exploring its potential for application in advanced solar panel recycling. In particular, the company says it will begin assessing the viability of high-yield recovery efforts targeting valuable materials such as silver, silicon and critical metals from end-of-life modules.

“At BMM, we are committed to building a future where sustainability and innovation go hand in hand,” said BMM Executive Director Fadi Diab. “Our investment in advanced recycling technologies, such as microwave-based delamination, is a strategic step toward that vision. This initiative not only enhances our ability to recover critical materials efficiently but also reinforces our leadership in the transition to a circular, clean-energy economy.”

Image credit: iStock.com/zstockphotos