News

On 26 June, SOLMATE hosted its very first clustering initiative, receiving the online visits of sister initiatives ForeSi and CRUSADE. Organised for project partners and advisory board members, the event welcomed over 40 participants with expertise in circular economy and recycling technologies for the photovoltaic (PV) sector, electric vehicle (EV) batteries and automotive components. The workshop addressed various topics common to all three EU-funded initiatives, from the supply and demand challenges to the integration of AI tools in the technological processes.

Turning waste into value. Projects’ snapshots

The event kicked off with a short presentation of each participating project. Starting with SOLMATE, the coordinator, Dr. Irena Kondratenko [VITO], outlined the project’s dual focus on EoL PV panels and EV batteries. To reach a truly circular economy, the project is navigating various other topics. It is developing protocols to assess the reuse potential of applications across three business models and piloting robotic dismantling technologies for PV panels.

CRUSADE, introduced by Dr. Iakovos Yakoumis [Monolithos], includes a consortium of 18 partners – renowned research institutions and industry players. The project targets to recover critical raw materials (CRMs) from end-of-life [EoL] vehicle components. CRUSADE has two pilot units under development, both aiming to recover 40 tonnes of CRMs while reducing the energy consumption by 80 % and cutting costs up to 15 %. Partners are collaborating towards these ambitions through pioneering an AI-driven sorting system that uses visual and XRF analysis to identify and classify materials before they reach the next metallurgical processes.

ForeSi, introduced by Monika Pilz, Senior Research Scientist at SINTEF, focuses on silicon recovery from PV panels. The project is testing applications potential for repair, reuse or recycle, backed by improved logistics and technical testing processes. Recovered silicon, ‘harvested’ through automated non-destructive dismantling and innovative purification, will reintegrate at a later stage the wafer production chain. FORESi also plans to replicate its demonstration operations across multiple EU countries and contribute with policy recommendations to address the slow flow of second-life PV panels.

Collaboration opportunities fuelled by overlapping objectives

The workshop surfaced four areas identified for cross-project collaboration:

1. Market dynamics. Supply insufficiencies: SOLMATE and FORESi both reported difficulties in sourcing sufficient volumes of decommissioned PV panels for the demonstration operations – a challenge identified in FORESi with the term “slow flow of PV panels”. Even when panels are available, dismantling operations often damage panels beyond reuse.
   When it comes to PV panels, SOLMATE’s problem extends also to recycling. The project faces difficulties sourcing glass with less than 500 ppm antimony (Sb), limiting the valorisation routes for recovered glass to sectors like construction.
   CRUSADE highlighted policy-related barriers in battery supply. Current practices prioritise steel and heavy metals recovery, often shredding valuable components like batteries and electronics. Their argument is simple and equally relevant: without adequate pre-treatment, valuable material is wasted along with the steel recycling processes and the opportunity to increase recycling efficiencies is missed.
2. Market dynamics. Demand: The demand side is equally complex, projects portraying various aspects: market readiness varies cross Europe. While Western and Northern Europe show growing interest for second-life applications, Eastern and Southern regions face infrastructure and policy gaps. Take Greece as an example, where high energy prices and more affordable PV panel technologies have led to a premature replacement of operating panels.
3. Policy gaps in recycling: The current EU Directive on end-of-life vehicles prioritises recovery of steel and heavy metals, neglecting lighter components like EV batteries and electronics. CRUSADE representatives underlined the need for legislative updates that would mandate the removal of components like printed circuit board assemblies [PCBAs] before shredding operations. SOLMATE, with its focus on EV batteries reuse and CRM purification in recycling processes, is considering a joint communication to raise awareness around the collection and sorting processes in the automotive sector.
4. AI for Circular economy: Projects are exploring AI in dismantling, sorting and material identification. If CRUSADE is applying it in their pre-treatment battery recycling processes, SOLMATE partners will develop AI algorithms to treat drone acquired images of PV plants; this will support the sorting of PV panels according to their performance and requalification potential. FORESi, though not yet integrating AI, plans to develop a PV collection framework that could feed future standardisation efforts.

Looking forward to a Circular economy in the EU

This initial clustering workshop surfaced a central tension: circular innovation cannot thrive without an involvement of all actors and, as a starting point, without a reliable supply of materials. When looking at PV panels and EV batteries, in both cases supply is scarce. We’re talking about a slow flow of PV panels and batteries often wasted in the automotive recycling processes that favours steel industry. Dismantling processes create significant challenges not only for PV panels, but for the repurposing and recycling of all electronic components. The path forward demands not only technological innovation but also supportive regulatory framework and market alignment.

AI may not offer a one-size-fits-all solution, but its integration into sorting and dismantling processes, seen in CRUSADE and SOLMATE, shows a shift towards automation and more efficient recycling processes. FORESi’s complementary approach, centred on collection frameworks and standardisation, add another layer to this evolving ecosystem.

This initial workshop generated additional discussion topics that could become the focus of  future meetings: the economic feasibility of reuse/recycling-based energy systems, the link between technical performance of these applications with market and regulatory conditions.