Continuous Electrolyte Jet Scanning Enabled Near-Quantitative and High-Purity Silver Recovery from Silicon Solar Cells

The accelerating retirement of end-of-life silicon solar cells (EoL-SSCs) is creating a rapidly expanding reservoir of secondary Ag, a critical yet finite resource, underscoring the urgent need for sustainable, high-efficiency recovery within a circular-economy framework. Conventional recycling routes are hindered by nonselective reactions, energy-intensive operations, and mass-transport bottlenecks. Here, we report a "top-down" electrolyte jet scanning (EJSC) strategy that enables selective, rapid Ag recovery while preserving the structural and functional integrity of the photovoltaic (PV) substrate. Tunable control of the interelectrode gap (IEG) and coordinated nozzle motion confines the reaction to a continuously refreshed microzone, allowing efficient and near-quantitative Ag extraction (97.1% in 4 min) from a 4 cm² cell area under mild conditions (2 V, 12 wt % HNO₃). Continuous interfacial renewal overcomes mass-transport limitations and produces kinetics that are significantly faster than those of static jet or bulk electrolysis systems. The dissolved Ag⁺ ions are directly reverse-electrodeposited with high efficiency (92.6% in 3 min) into Ag powders of 3<i>N</i>-level purity (99.88%), demonstrating potential as functional fillers for advanced electronics. EJSC also maintains high current efficiency throughout the operation (extraction, 89.6%; recovery, 79.6%) and sustains high Ag yield (>91%) over six repeated treatments, validating its strong industrial feasibility and scalability. Life-cycle and techno-economic assessments (LCA-TEA) further reveal that the process robustness of EJSC leads to markedly lower environmental impacts and significantly enhanced economic returns (>2500 USD/(kg of Ag)) relative to conventional processes. The confined-jet architecture inherently accommodates the thin, chemically sensitive passivation stacks used in emerging PV technologies. Integrating laboratory-level precision with industrial-scale throughput, EJSC delivers a closed-loop pathway for PV waste upcycling and establishes a versatile, sustainable platform for future urban mining of critical metals.