Repowering vs. Recycling: What to Do with Old Solar Panels

The solar energy industry has become very established in the last 15 years and plays an integral part in how we produce, store, and distribute power. Most of us are familiar with rooftop solar and solar farms as they have spread far and wide across the UK. However, we have now reached a point where we need to consider how to renew the renewables.

Like most things, solar panels get old, and their output deteriorates. In many cases it makes sense to invest in reversing this degradation which is where solar repowering comes into play. 

Repowering a solar system involves upgrading or replacing parts of an existing solar power system to improve its efficiency, performance or extend its operational life. This is often done by replacing older components with newer, more efficient technology. The aim is to reoptimise based on the latest available technological updates. For example, in the last few years scientists have developed pyramidal lenses that are designed to rapidly concentrate solar intake, reduce space taken up on farms and provide room to scale. 

Repowering solar panels or upgrading them with newer more efficient technology is often a preferable option to recycling them as it will increase the lifespan of solar installations and improve energy production. It can also be more cost-effective in the long run especially when you take into consideration the environmental impact of recycling and manufacturing. 

Most solar panel manufacturers guarantee a lifespan of 25-30 years for their products. Yet, most solar panels will continue to produce energy after this period but at a much less efficient rate year on year. Bearing in mind that the industry standard payback period for solar panels is currently between 6 and 10 years, repowering presents an economically attractive and simple way of keeping models active and efficient. 

Here are some common forms of solar repowering:

• Removal of obsolete inverters and replacing with newer more efficient ones
• Replacing older, less efficient solar panels with newer high-efficiency panels
• Redistributing the system
• Refining grid connection
• Changing the system’s electrical configuration. Upgrading the wiring and cabling to improve performance
• Replacement of the balance of system components 
• Installing new software platforms. Adding or improving monitoring and control systems.

Solar repowering is not just a solution for damaged and degrading panels but also comes with a range of benefits to upgrade your solar plant. 

Here are some benefits of repowering solar panels:

• Increased efficiency: Newer solar panels and inverters offer higher energy conversion which means that they can produce more electricity from the same amount of sunlight.
• Reduced performance decline: Repowering can help mitigate the natural degradation of solar panels leading to an increase in energy production.
• Extended lifespan: The repowering process can help extend the operational life of a solar system by replacing outdated technology with up-to-date panels. These are durable efficient systems that can continue to generate power for many more years. 
• Access to new technology: Technology has evolved rapidly since the early days of solar. New models have significantly improved performance and efficiency. Solar plant owners can take advantage of the most up-to-date advances in solar technology, such as higher efficiency panels, smart monitoring systems and better energy management capabilities when repowering. In addition to that there are also new innovative battery systems. 
• Sourcing critical components: Sometimes it can be difficult to find replacement parts for older systems due to legacy manufacturers leaving the market. The longer panels are untouched is proportional to the number of unavailable vital components. Your solar panel system could be compromised permanently. Repowering means that newer more readily available components can be used.
• Decreased downtime: The risk of system failures and downtime is minimised by replacing older, unreliable components with newer more robust ones.
• Financial Incentives: While there’s an initial cost to repower, it can lead to long-term savings by increasing energy production and reducing maintenance costs. There is a further incentive for keeping solar panels efficient and up to date with the Smart Export Guarantee which pays producers for excess electricity exported to the National Grid. 
• Remaining compliant: Repowering can help ensure that a solar system complies with evolving regulations and standards.
• Environmental advantages: The need for new panel manufacturing or the recycling and disposal of old panels with the associated environmental cost can be reduced by repowering. Maximising energy generation further reduces the carbon footprint of running solar panel devices. 

Although there are many benefits to repowering your solar system there are also challenges and considerations to think about as follows:

• Financial costs: The average commercial solar panel payback takes 6-10 years. Upkeep through repowering, however, will add costs on top of the initial investment. Not making this investment would be false economy as it is vital for keeping systems efficient and producing energy at the standard rate.
• System balance: Mixing new and old solar panel models within one project can cause issues with batteries and inverters. Any imbalance can cause maintenance problems. If this is the case, it can be more efficient to conduct a full-scale update.
• Waste management: Solar repowering usually involves the replacement of outdated parts with new ones which raises the issue of what happens to the old solar panel components.
• Complex disassembly process: The main components of solar panels are glass, plastic and aluminium which are all recyclable. However, recycling silicon solar panel modules requires a more careful disassembly process. The technical side of this process can be delicate and time-consuming.
• Legalities: There are different regulations for ground-mounted PV systems and rooftop PV systems.

The only alternative to repowering is to replace the entire system creating large wastage and a decreased return on investment. 

The solar industry often struggles to deal with the many legal obligations in relation to the disposal of photovoltaic (PV) panels. Although the cost of removing and disposing of solar panels as part of decommissioning will most likely have been considered from the beginning of the project there often isn’t an agreement in place as to who within the supply chain is responsible for the disposal costs. A decision should be made as to who is responsible for disposal costs when the contract is being negotiated to avoid confusion and potential disputes. This will also ensure compliance with the relevant legal framework: the UK’s Waste Electrical and Electronic Equipment (WEEE) regulations 2023.

Quite often, there is a lack of understanding about what is required by the WEEE regulations. Generally, contracting parties only appear to discuss disposing of the panels and the costs at the time of disposal. 

In fact, agreeing a costs position becomes relevant as soon as the panels are supplied to the UK market by a producer. The producer should register with a regulator and compliance scheme at that point and should pay annual fees to these bodies to cover the disposal costs of those panels in future. 
Due to a misunderstanding of the requirements and non-compliance by producers, there’s a risk that developers are left to deal with the waste and meet the disposal costs.

Here are some of the challenges of recycling:

• Complexity: The recycling of solar panels can be a complicated process. It can require specialised equipment and the right expertise to separate and process the different materials.
• Cost: The recycling of solar panels can be expensive, and the cost may not be fully recovered through the sale of recycled materials.
• Limited market: Relatively speaking the market for recycled solar materials is still quite small. There is simply not enough demand to support large scale recycling operations. 
• Environmental impact: There is an environmental impact associated with the manufacturing and disposal of solar panels and although recycling can help mitigate some of the impact, it’s not the perfect solution. 
• Hazardous materials: Some solar panel technologies contain hazardous materials, such as lead and cadmium, which require special handling and disposal. 

Both repowering and recycling are essential for ensuring the long-term sustainability of the renewable energy sector. Repowering makes the most of the potential of existing infrastructure, while recycling ensures responsible end-of-life management and resource recovery. To achieve a truly sustainable and circular renewable energy system a combined approach is vital.