By Ellie Peichel (Plug In America) and Jessica Dunn (Union of Concerned Scientists)
The number of electric vehicles (EVs) on our roads has been increasing at an extraordinary rate, reaching 9.5 million EVs sold worldwide by 2023. The EV revolution offers many benefits, including reducing greenhouse gas emissions from the transportation sector.
At the end of an EV's 10-15 years, the lithium-ion batteries that power the vehicle typically last about 70-80 percent their original strength. At this point, there are many excellent options for the battery: it can be reused, recycled, or recycled. Battery recycling includes using batteries in the same system installed directly in another vehicle; recycling involves using batteries in a completely different system such as static energy storage, and recycling is the process of recovering minerals to make new batteries.
Battery recycling and battery recycling have major environmental benefits because they reduce the need to manufacture new batteries and extend the useful life of existing ones. Repurposing is getting a lot of hype in all the second life solutions as it is an excellent option that uses old EV batteries to support the renewable grid. But let's first talk about an often glossed-over option—EV battery reconditioning and recycling.
EV batteries can be repaired and recycled.
Battery reuse occurs when repaired battery packs are reused directly in another EV system, such as in a vehicle that requires short driving distances. Repairing batteries is similar to refurbishing other electronics – malfunctioning parts are repaired/replaced to restore functionality.
Over the past decade, EV battery technology has advanced significantly, increasing the range of batteries. Because of these improvements, repurposing and repurposing is becoming a more viable option. By 2023, the average EV range is reached 270 miles for 2023 models. That's almost 200 miles more than a decade ago, and future batteries will continue to improve!
As more EVs enter the market and older EVs reach the end of their useful lives, there will be an influx of used or retired battery systems that need processing. Battery repair and recycling can be used as tools to extend the life of a vehicle's system. This, in turn, would reduce the need for new EVs and batteries, reducing the use of minerals as well the implications.
It is also designed to be recycled for use in stationary storage.
EV batteries can also be intended for different applications. As the electrical grid transitions to renewable energy, more stationary storage batteries are needed to ensure that electricity is always available. After the battery is used in an EV, it is removed from the vehicle and tested several times to determine its health and suitability for stationary use. When in good condition, the battery is connected to several others to form a more comprehensive battery system. Many of these systems support solar arrays, such as the B2U system in the image below.
Source: Report of the CA Lithium-ion Battery Recycling Advisory Group. This is 25 MWh of storage capacity made up of 1,300 pre-installed EV batteries tied to a solar farm in Lancaster, California.
What are the barriers to reuse and recycling?
Refurbished and recycled batteries compete with new batteries on the market, which have been dropping in price due to innovation. This innovation is great for the EV and stationary storage market. However, because there are currently expensive barriers to the second-life market, in some cases, it is cheaper to buy a new battery than a refurbished or recycled one.
These expensive barriers can be divided into several stages that follow the process of repair and rework: transportation, inspection, and dismantling. Solutions to these obstacles are provided in the next section.
Additional travel costs
Once the batteries are removed from the vehicle, they are classified as hazardous waste. See therefore, they are regulated by regulations governing the transportation of hazardous waste (which is often very expensive). There is currently no separate waste category for lithium-ion batteries or a testing process to certify a used battery as safe for second life. Therefore, we cannot handle and ship these batteries in the same way as a new battery entering the market. EPA will propose new rules the designation of waste to improve the management and recycling of batteries, which may solve this problem.
It's hard to untangle
The EV battery is not designed to be disassembled, making it difficult to remove. They are also not standardized across makes, models, and model years; therefore, the process cannot be automated. Some rebranding companies forego the liquidation process because of the time and cost involved; instead, they use a full battery pack, as seen in the image above. Using a full pack may reduce disassembly costs, but the loss of battery efficiency is associated with not removing bad cells or combining cells based on their capacity.
A lengthy screening process
To determine if the battery is ready for use again, it is important to know battery characteristics such as temperature, voltage, and power. Gathering this information was previously active most of the time and required charging and recharging of the battery during use. Startups now run tests to determine these necessary data points in just a few minutes, significantly reducing the time and associated costs.
Of course, all batteries must eventually be recycled.
Finally, all batteries should be recycled. Minerals recovered from recycling can be used to make next-generation EV batteries, eliminating the need for newly mined minerals. This is important to reduce the environmental and social harm associated with mining and expansion complete stability of EVs. While recycling is beneficial, it's important not to skip steps to recycle and recycle. Research has shown that it is more beneficial for the environment to recycle battery packs before recycling, even if the mineral energy of the batteries increases.
Policy solutions to increase reuse and recycling.
The US does not need to reinvent the wheel in terms of policies that improve circulation in our battery supply chain. We can look at European Union Battery Law for guidance on the many policies that help facilitate battery reuse, reconditioning, recycling, and ultimately, recycling. Below are some of these policies:
Extended producer responsibility (EPR)
Extended manufacturer responsibility makes the automaker responsible for ensuring that retired batteries are reused, recycled, or recycled at the end of their life in an EV. If this requirement is imposed on car manufacturers, they are more likely to design batteries and the collection process to increase efficiency and thus reduce end-of-life management costs.
Designing to disassemble
Disassembling EV batteries is an important step in recycling, reuse, and recycling. As noted earlier, it is complex with design variations, design complexity, and safety issues arising from different end-of-life scenarios. For example, within individual EV battery modules, cells are usually glued or welded together. This makes it very difficult or impossible to replace the dysfunctional cells individually. The solution lies in designing batteries to make them easier and safer to disassemble later.
Battery labeling
Battery labeling is an important step in ensuring that all players in the battery supply chain have access to the information they need. Battery labels convey information about battery materials, chemistry, and design.
Digital battery indicator
A digital identifier for each battery can make the data necessary for reuse, recycling, and re-accessibility. This information includes battery life statusbattery chemistry, recycling content, and other important environmental and human rights information on batteries. The Global Battery Alliance is working with the EU to create a Battery Passport to fulfill the requirements of the EU Sustainable Batteries Act. The US could use something like Battery Passport to ensure transparency, support end-of-life processes, and track the entire life cycle of batteries.
Let's build a sustainable energy and transportation system.
Promoting EV battery repair, reuse, and recycling in conjunction with recycling is critical to establishing a sustainable and circular battery economy. By extending the lifespan of EV batteries through recycling and reconditioning, we greatly reduce the impact associated with battery production and disposal. Reusing EV batteries in secondary applications beyond automotive use increases their value and utility. Although no longer suitable for primary EV operation, these batteries still have a large energy storage capacity suitable for stationary storage systems.
By extending the life of EV batteries and providing second life opportunities, we can reduce the impacts of battery production by reducing battery demand. new batteries. Regardless of whether batteries are reused, batteries will eventually need to be recycled. Recycling can help reduce the impact on communities along the battery value chain while strengthening the EV supply chain. This can be achieved by increasing our domestic supply of energy-transforming minerals and reducing our need to mine basic materials. By adopting these practices that promote a circular battery supply chain, we address pressing environmental challenges, unlock new economic opportunities, and pave the way for a sustainable and resilient energy future.