OnePlanet has unveiled a proprietary, fully automated recycling technology designed to reclaim high-purity materials from decommissioned solar modules. Known as Photovoltaic Recycling through Integrated Systems and Mechanics (PRISM), the mechanical process eliminates the need for chemical or thermal separation. By isolating components effectively, the system recovers high-grade aluminum, copper, and silicon that contains significant concentrations of silver. This advancement allows the company to produce a silicon stream exceeding 95% purity, which serves as a valuable feedstock for metallurgical-grade silicon production while simultaneously reducing the energy and emissions typically associated with processing virgin raw materials.
The PRISM system, which has successfully completed engineering trials, is scheduled for installation at the company’s Florida facility in 2027. The technology builds upon two years of operational experience at a demonstration site in Green Cove Springs. During testing, the mechanical process achieved a 99.5% removal rate for module glass while maintaining high purity levels. By concentrating silicon- and silver-bearing materials rather than crushing them into mixed streams, the system ensures that recovered components remain highly saleable. The process maintains consistent performance across both monofacial and bifacial modules, regardless of whether the panels are intact or damaged by storms.
Beyond glass recovery, the downstream stages of the PRISM process yield copper granulate at 99% purity and aluminum at 99.9% purity. The recovered silicon stream, which carries approximately 1% silver, represents a significant resource for the company. CEO André Pujadas noted that this silver concentration is substantial, effectively functioning as a high-grade ore. Because the silicon reaches such high purity levels before further refining, it requires less energy to reach metallurgical-grade specifications compared to traditional methods that rely on quartzite.
To support the construction of its industrial-scale River City facility, OnePlanet secured a $14.5 million investment tax credit through the federal Qualifying Advanced Energy Project program. This facility will host the first fully integrated PRISM production lines. Looking ahead, the company is developing a refining process targeted for 2030 that will allow it to extract silver as a finished product directly from the silicon stream. Once this refinery is operational, OnePlanet intends to consume its own recovered silicon internally, marking a strategic shift from simple materials recovery into the broader metallurgical-grade silicon and silver refining markets.