Retired EV Batteries Move to Storage or Recycling After Removal, Engadget Reports

When an owner is done with a vehicle for any reason, the battery may no longer provide the original range, may have developed a fault or may have been damaged in a crash. Even if the owner replaces it, specialists known as EV battery diagnosticians or technicians inspect and test the pack to determine what comes next.

In some cases, repair is possible. An EV battery pack contains individual cells, typically grouped in modules. Depending on the design, a technician may be able to replace a module or component instead of sending the entire pack to recycling or repurposing. A safe and reliable used EV battery can potentially be reused in a compatible vehicle. But repair does not always work out. Some EV packs are difficult to repair, especially if the vehicle was in a serious accident that resulted in a total loss.

For the most part, an EV battery enters a repair or reuse operation after removal. Its condition determines whether it becomes stationary energy storage or goes to a recycler. Engadget reported there is no single answer, only possibilities based on the battery's status.

A battery that no longer delivers the range an owner wants can still be useful. Retired EV batteries can retain as much as 70 to 80 percent of their original capacity if they are not damaged. A common option is stationary energy storage, where the battery supplies backup power for a building or helps balance electricity supply and demand on the grid. California, for example, is using Nissan Leaf and Honda batteries to store solar energy.

Repurposing is not always simple. After a technician thoroughly inspects the battery, suitable components and any controls and safety equipment needed for its new home must be integrated. The process is costly, so a viable battery may still be recycled if the cost is more than the return.

Repair and repurposing are not suitable in every case. If neither is an option, the pack is prepared for safe processing and dismantled. Materials such as steel, aluminum and copper are stripped out and recovered. Cell processing typically involves shredding and separation, producing a mixture of "black mass." This black mass contains electrode materials that eventually go through more processing to recover valuable ingredients.

The battery's chemistry dictates the next stage, which may include heat or chemical solutions to extract more material. Because not all batteries are identical, the outcomes will include varying amounts of material, most of which will return to manufacturing. Recycling is costly, requires a lot of energy and results in losses during the procedure. It also reduces demand for mined resources and, according to Engadget, means less environmental impact.

Editor's Summary

Engadget reported that electric vehicle batteries removed from cars can be repaired, reused, repurposed as stationary storage or recycled. The path depends on battery condition, design and cost, with retired packs sometimes retaining 70 to 80 percent of original capacity. Recycling recovers materials but remains costly and energy-intensive, while repurposing can extend battery use on the grid.