With battery electric vehicles (BEVs) becoming more common worldwide, a joint team of researchers has conducted a study to determine the best way to handle used electric vehicle batteries. Composed of thousands of lithium-ion cells, these packs have an estimated lifespan of 10 to 20 years, which can be affected by driving habits, battery chemistry, maintenance, and environmental conditions.
After their primary automotive use, EV batteries can continue to operate for up to a decade in secondary applications before being recycled into new battery materials.
Researchers from the Fraunhofer Research Facility for Battery Cell Production (FFB), the Lawrence Berkeley National Laboratory, and the University of Münster explored which option offers greater benefits: reusing second-hand electric vehicle batteries in stationary energy storage systems or immediately recycling them for raw materials.
As the world continues to adopt renewables, which produce electricity intermittently, stationary energy storage is increasingly critical to a successful green transition.
To help address renewable intermittency, used EV batteries could be repurposed as energy storage units after their automotive life ends. This low-cost approach would allow the batteries to support homes, renewable power plants, and the grid, storing excess energy for use during peak demand. Even with a residual capacity of 70% to 80%, these batteries remain sufficient for stationary use. The researchers estimate that by 2030, second-life batteries could meet the entirety of stationary energy storage demand.
Alternatively, the batteries could be dismantled to recover valuable raw materials like nickel, cobalt, and lithium for manufacturing new EV batteries. Recycling not only reduces waste and environmental impact but also helps the United States and other Western nations reduce dependence on Chinese-controlled supply chains for critical minerals.
The study found that by 2050, California could meet roughly 61% of its new EV battery demand by recycling old packs into fresh battery materials.
When comparing environmental outcomes, second-life use delivered greater greenhouse gas savings. The study estimated that California could avoid 55.8 million metric tons of CO₂-equivalent emissions through second-use strategies, compared to 48.3 million metric tons through immediate recycling.
Still, the researchers recommend expanding recycling infrastructure early and adopting a hybrid approach, combining reuse and recycling, to maintain a stable battery supply for vehicles and energy storage systems alike.
The study concludes that a balanced approach which prioritizes second-life applications before recycling is the most sustainable path. This strategy conserves resources, maximizes emission reductions, and supports a circular economy for EV batteries. As global EV adoption accelerates, regions that adopt hybrid battery management models for used EV batteries could set the standard for a cleaner and more resilient energy future.
It would be interesting to hear what EV makers like Bollinger Innovations, Inc. (NASDAQ: BINI) think about creating an ecosystem that leverages end-of-life electric vehicle batteries for recycling.
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