Towards Circularity in Solar Energy: A Comparative Life Cycle Assessment of Innovative & Conventional PV Modules

Abstract

Given the increasing share of renewable energy, particularly solar power, there is a growing attention to resource use and disposal challenges associated with Photovoltaic (PV) modules. PV modules consist of multiple layers of materials like silicon, silver, aluminum, glass, and polymers, which makes them difficult to dismantle and recycle. Many recycling methods involve toxic chemicals and create hazardous byproducts, raising environmental issues. These concerns are compounded by the energy-intensive nature of PV’s manufacturing process. Despite the clean energy that PV modules bring, their production process remains heavily reliant on fossil fuels, particularly coal, where electricity (mainly from coal) accounts for about 80% of the energy used in energy-intensive processes. Furthermore, with the global market being dominated by China, attention should be drawn to issues related, supply chain vulnerabilities, and the environmental impact of long-distance sea transport to end-users.
This study conducts a Life Cycle Assessment (LCA) of an innovative photovoltaic (PV) module developed by the Swiss company LightSeeds. In this module, the traditionally used aluminum and glass are replaced with alternative materials and the module is assembled in Switzerland. The innovative design choices aim to reduce environmental impact by lowering weight, minimizing resource use, substituting with low-energy and low-impact alternative energy sources for the fabrication process, and enhancing recyclability. Using a standardized methodology aligned with ISO and LCA standards, this research evaluates the circularity and environmental footprint of the intended PV module compared to the conventional ones.
With the data provided by manufacturers on supply chain and production process, the environmental emissions associated with the PV panel were calculated. This assessment was conducted using SimaPro software, Ecoinvent database and other relevant data to support environmental product declaration (EPD) creation and impact analysis in accordance with EN 15804+A2 and ISO standards. The aim was to prepare data for the LightSeed’s PV module in a way that closely aligns with the structure and principles of an EPD. While it will not be an official EPD, the data will be calculated and presented in a way that moves toward that direction, offering a comprehensive view of the environmental impact and enabling the author to make the comparison with other commercial PV modules.

Popular Abstract

PV modules, also known as solar panels, are devices that convert sunlight into electricity using the photovoltaic effect. They offer the advantage of generating electricity with lower environmental impact compared to fossil fuels, yet this clean energy harvested from the sun places a burden on natural resources. PV modules have high material-related environmental impact because they require various precious, rare, and toxic materials. As demand for solar power grows rapidly, driven by climate targets and renewable energy policies, the environmental footprint of PV modules becomes an important issue.
Conventional solar panels are made primarily of glass and aluminium, which together make up around 80% of the total panel weight. These materials are recyclable but recycling them still consumes energy. The polymer layers inside panels, used to protect them from moisture, UV rays, and mechanical damage, are particularly difficult to recycle. Moreover, most PV modules are produced in China, where the electricity grid is still heavily dependent on fossil fuels, making the manufacturing process highly carbon intensive.
This study investigates a new type of solar module that aims to bring less environmental footprint. The innovative design removes glass and aluminium entirely, replacing them with recyclable polymers and cardboard. A part of the fabrication is done in Switzerland, where the electricity grid is cleaner. The lighter weight and manufacturing in Switzerland also means lower emissions from transportation, especially when modules are installed in Europe.
To understand the environmental impact of this new design, a life-cycle assessment (LCA) was carried out. This method, based on international (ISO) and European standards, examines every stage of the product’s life, from raw material extraction to manufacturing, transportation, assembly, and end-of-life recycling. The operational phase (electricity generation) was not included. Since real-world production data for the new module was not yet available, the study used estimates from similar and public LCA data. This makes the assessment less precise but valuable for early-stage evaluation before large-scale production.
To measure potential benefits, the results were compared with four commercially available PV modules, all with verified environmental product declarations (EPD). To ensure a meaningful comparison, selection criteria were applied to match similar product types and system boundaries.

What did the study find?

The production phase, especially the sourcing and processing of raw materials, accounts for about 90% of the total environmental impact of a PV module. At this stage, the new glass-free, aluminium-free design outperformed than other four traditional modules. The environmental impact from transportation was also reduced, thanks to the module’s lower weight and more localized supply chain. By eliminating heavy materials and choosing recyclable alternatives, manufacturers can reduce emissions, lower resource use, and simplify recycling at the end of the product’s life.

• author: Askari, Mahdi
• supervisor: Ulla Janson
• organization: Division of Energy and Building Design
• course: AEBM01 20251
• year: 2025
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Solar Energy, Life cycle Assessment (LCA), Environmental Impact, PV Module, Environmental Product Declaration.
• language: English
• id: 9197051
• date added to LUP: 2025-06-12 10:09:58
• date last changed: 2025-06-12 10:09:58