Battery Recycling and Second-Life Batteries

What Happens to Old EV Batteries?

An EV battery that has reached the end of its time in a vehicle is not automatically worthless. First, the condition of its cells and modules is assessed, along with its remaining capacity. The results determine what can happen to the battery next.

This distinction is particularly important for lithium-ion batteries. Even if a battery can no longer meet the demanding requirements of an electric vehicle, it may still be suitable for less performance-intensive applications. If further use is no longer practical, the battery is sent for professional recycling.

Second-Life Batteries: How Reuse Can Extend the Battery Lifecycle

When batteries are given a second life, suitable battery packs or individual modules are repurposed for new applications after their use in an electric vehicle. A second-life battery can, for example, be used as stationary battery storage. In this setting, requirements for power density, weight and usage differ considerably from those of a battery installed in an EV. Fraunhofer is already conducting targeted research into second-life models and applications for used vehicle batteries.

Before a battery can enter a second-life application, however, its performance and safety need to be assessed. Condition monitoring, dismantling and controlled discharging all play an important role. This can significantly extend the useful life of suitable batteries beyond their original application in a vehicle.

How Are EV Batteries Recycled?

EV battery recycling involves several stages. First, the used battery is safely discharged and removed from the vehicle. Specialist facilities then dismantle the battery system, separating the housing, cables, electronics and battery modules. Only then does the actual processing of the battery cells begin.

Depending on the recycling method, the cells may be mechanically shredded before their individual components are separated. Thermal or chemical processes can then be used to recover valuable materials. These include lithium, nickel, cobalt and copper.

Recycling lithium-ion batteries is therefore a complex, multi-stage process. The aim is to recover as many raw materials as possible from used batteries and make them available for use in new products. EV battery recycling can therefore help keep valuable materials in circulation for longer.

Why Is Battery Recycling Important for Sustainable E-Mobility?

As the number of electric vehicles grows, so too will the number of batteries that eventually need to be reused or recycled. Effective battery recycling is therefore becoming an increasingly important part of e-mobility. Alongside the expansion of electric vehicles, power grids and charging infrastructure, it raises another important question: how can the resources already in use be retained for as long as possible?

Battery storage also plays an important role elsewhere in the e-mobility ecosystem. JOLT uses integrated battery storage in its ultra-fast charging solutions, for example, enabling high charging power even in locations where existing grid capacity is limited. Applications like these demonstrate just how versatile battery systems can be within e-mobility. This makes it all the more important to consider their entire lifecycle – from production and use through to recycling.