EV batteries: Repair, refurbish, repurpose, recycle

This project will investigate and develop solutions for sustainable repurposing of used lithium battery modules from electric vehicles (EV), including mining trucks, buses, and cars.

It will aim to rigorously assess EV battery conditions, such as the remaining capacity and performance characteristics, through advanced monitoring and testing, selecting only high-value modules to minimise waste and costs.

These repurposed modules will find second life in applications like household energy storage, grid support, mobile power, enhancing sustainability and efficiency. This will extend the useful life of these batteries and contribute to a more sustainable and efficient energy ecosystem.

Participants

• Magellan Powertronics Pty Ltd
• Edith Cowan University

Project background

As the world moves towards a greener and more sustainable future, the rise of EVs has been remarkable. EV batteries are a systematic enabler of a major shift to bring transportation and power sectors to carbon neutrality. However, this transition comes with a major challenge: the responsible management of retired lithium-ion batteries.

Hybrid and EV sales are expected to increase 30-fold by 2030 in comparison to 2019. There will be a significant increase in the number of retired EV batteries. Therefore, the handling of batteries responsibly and sustainably becomes a major challenge for all relevant industries.

Recognising this need, Magellan has initiated and been developing the 4R ecosystem, specialising in the Repair, Refurbishment, Repurposing, and Recycling (4R) of lithium batteries, from cars, trucks and buses to mining haul trucks and electric vehicles.

The aims of the 4R ecosystem are to:

• extend the battery’s useful life, reducing the requirement for new battery production. This helps conserve valuable resources, reduces energy consumption, and minimises the environmental impact of battery manufacturing and disposal, providing environmental benefits.
• provide cost savings by repurposing batteries that still have significant capacity and performance. It can lower expenses for various applications, from energy storage to electric vehicles.
• reduce electronic waste (e-waste) and the associated environmental hazards. This aligns with sustainability goals and reduces the burden on waste management systems.
• provide valuable support to the energy grid, helping to stabilise it by storing excess energy during low-demand periods and releasing it during high-demand periods.
  •contribute to a circular economy, where products and materials are reused and recycled, promoting sustainability and reducing the consumption of finite resources.

In summary, the 4R ecosystem provides a sustainable and cost-effective approach that benefits both the environment and the economy by extending the life of EV batteries and finding new uses beyond their initial application.

The success of the 4R ecosystem depends heavily on optimal battery repurposing solutions which need to address the following key challenges:

• Mismatch of requirements: batteries are highly optimised for the first life of an electric vehicle, but the demands for the next life (reliability, longevity) are drastically different.
• Second-life battery system development: the development must address and link all domains (electrical, thermal, mechanical, ageing, and safety) together. A highly complex requirement structure must be considered during development.
• Battery availability and diagnostics: status and variability of retired batteries are unclear.

This project aims to address the abovementioned challenges.

Project objectives

The objective of this project is to address the challenge of repurposing retired lithium-ion batteries sourced from EVs, including mining trucks, buses, and cars.

It will develop a cost-effective and sustainable solution to managing the retired batteries through repurposing, extending them into the second life applications (UPS, energy storage systems, or grid support), and maximising their value and functionality whilst also contributing to a more sustainable energy future.

Please note …

This page will be a living record of this project. As it matures, hits milestones, etc., we’ll continue to add information, links, images, interviews and more. Watch this space!