The IEA PVPS, in a new report, finds that repairing and reusing solar PV modules is technically possible
Challenges exist in the form of labor-intensive and costly processes that limit the use of second-life modules at scale
Large-scale deployment requires automated testing systems such as I-V characterization and EL imaging
Refurbished modules have to compete with rapidly falling prices of new panels
Pairing second-life modules with second-life batteries has benefits, but these have limited cost advantages over new batteries
A new technical report by the International Energy Agency Photovoltaics Power Systems Programme (IEA PVPS) finds that second-life solar PV modules are technically feasible for use in the circular economy, but face scaling challenges owing to economic and regulatory barriers.
Global solar PV deployment has already crossed the 2 TW level and is expected to add several more TWs by 2030, and further on. Efforts are being made to address future waste management, and recycling and reusing solar panels is one approach that is seen as carrying weight, but it comes with its own set of challenges, according to the IEA PVPS.
Published under Task 13-Reliability and Performance of Photovoltaic Systems, the new report provides a technical review of repair, refurbishment, and reuse strategies to extend the operational life of solar PV modules.
According to the report, PV module repair in terms of solder bonding failure, cracked backsheets, or junction box use is technically feasible. The challenge is that this process is usually labor-intensive, expensive, and difficult to scale without support from an automated testing system.
Solar module repair requires automated testing systems that are capable of I-V characterization, electroluminescence (EL) imaging, and conducting insulation resistance testing. “This approach allows efficient classification into “reuse,” “repair,” or “recycle” streams, minimizing labour costs and ensuring greater consistency,” stress the writers.
Solreed, ENGIE Green, and CEA INES have seen the ‘detect-repair-reuse’ approach work at the pilot repair line at the French institute’s facility, which they claim can extend the lifespan of a PV module by at least another 10 years, as per the report.
Moreover, when refurbished modules are repaired and reused with second-life batteries, they can perform well enough to generate energy for self-consumption, as observed in some pilot projects. For consumers, these also reduce exposure to volatile electricity prices while lowering GHG emissions.
The economics of second-life batteries remain a concern, though, since the cost difference relative to new batteries is not significant.
The authors highlight that the second-life PV market remains fragmented and underdeveloped due to the absence of standardized qualification criteria, testing protocols, and repair guidelines. These factors significantly limit transparency, comparability, and trust in reused products.
Second-life PV modules are typically requalified through visual checks, electrical performance tests, and sometimes safety testing to assess remaining performance and compliance. However, some online platforms sell second-life modules without such verification, which the authors underline raises concerns about their reliability, safety, and long-term performance.
A big challenge arises on the cost front. Second-life PV modules, with their expensive refurbishment costs, have to compete with rapidly falling costs of new modules. The IEA PVPS recommends incentivizing or subsidizing the use of such modules.
Expanding the use of second-life solar modules also requires well-defined regulations, funding programs, and circular economy requirements.
Another recommendation is to start from scratch. Manufacturers should design PV modules that are easier to repair and provide clear bills of materials (BOMs), which will be ‘critical enablers’ for the widespread use of second-life modules.
“Without clear technical standards, second-life PV modules face barriers to large-scale adoption, insurance coverage, and bankability. Moving forward, alignment with international frameworks (e.g., IEC standards) and the development of robust pass/fail criteria are essential to ensure safety, reliability, and traceability,” recommend the writers.
The complete report, titled Performance and Reliability Aspects of 2nd Life Photovoltaic Modules, can be downloaded for free on the IEA PVPS website.