What Happens to Old EV Batteries? From Vehicle to Second Life Uses
This image is sourced from Plugin Garages
As you may have heard, the government has set out a plan to reach Net Zero by 2050, this involves stopping the production of new petrol and diesel cars in 2030. In addition to that, a Zero Emission Vehicle mandate has been introduced in 2024, requiring all car manufacturers to guarantee a percentage of their sales must be fully electric.
The demand for electric cars has been rising fast over the last few years, and in 2022 they accounted for almost a fifth of new car sales - growing to 22% more recently - so we are getting closer to a greener environment. As more people make the switch to electric, you may be wondering what happens to the batteries once they no longer have the capacity to power a car. Well, in this article, we’ll explore what happens to EV batteries and how they’re being repurposed and recycled in a sustainable way.
Image from SMMT
Did you know…
Over the lifetime of a typical internal combustion engine (ICE) vehicle, it burns around 17,000 litres of petrol or 13,500 litres of diesel?
To put this into perspective, a study by Transport and Environment suggests that if all that oil were stacked in barrels, it would form a tower 70-90 metres high — roughly the equivalent of a 25-story building. This highlights the immense environmental cost of traditional petrol and diesel cars, which emit harmful CO2 and pollutants that contribute to climate change.
However, the rise of electric vehicles presents an opportunity to significantly reduce these emissions. The more electric vehicles we see on the roads, the closer we get to a greener environment.
EV Batteries: How They Work
When it comes to electric vehicles, the heart of the car is its battery — typically a lithium-ion battery. These batteries store and release energy to power the vehicle’s electric motor. But unlike traditional car batteries that power a vehicle’s electrical systems, EV batteries are far larger, more complex, and designed to last for many years.
How Lithium-Ion Batteries Work in EVs
Lithium-ion batteries in EVs work through the movement of lithium ions between two electrodes (the anode and cathode) within the battery. When the battery is charged, lithium ions move from the cathode to the anode, and when the battery is used to power the car, these ions move back to the cathode, generating an electrical current that powers the motor. This process is what allows electric cars to run smoothly and efficiently.
Comparison to Traditional Car Batteries
Traditional car batteries, which are lead-acid batteries, are primarily used to start the engine and power electrical components like lights and radios. These batteries are much smaller and less sophisticated than the lithium-ion batteries used in electric vehicles. While lead-acid batteries can last 3-5 years before they need replacing, lithium-ion batteries in EVs can last much longer — typically 15-20 years. This longer lifespan is one of the key reasons EVs are seen as more sustainable in the long term.
Key Components in EV Batteries
Lithium-ion batteries are made up of several key components, including:
Lithium: A lightweight metal that’s crucial for the battery’s ability to store energy.
Cobalt, Nickel, and Manganese: These metals help improve battery efficiency, lifespan, and energy density.
Graphite: Used for the anode material, graphite plays a critical role in the movement of lithium ions.
Electrolyte: A chemical substance that enables the movement of ions between the anode and cathode.
As demand for electric vehicles increases, sourcing these materials has become an important challenge. To mitigate this, the industry is focusing on improving battery recycling and reducing the need for new materials through sustainable practices
The good news is, only 30 kg of original raw material would be lost once you take into account the recycling of the materials and that most of the metal content is recovered. This is about the size of a football!
According to SMMT’s 2024 Automotive Sustainability Report, from 2015 car manufacturers were required to ensure that 95% of the vehicle (by weight) is recycled, re-used or recovered. So, as most electric car batteries have a lifespan of 15 to 20 years, after which manufacturers have to find a way to sustainably dispose of them. It is worth noting that manufacturers are obliged to take back their vehicles, when they become end-of-life.
Sometimes a battery is recycled
Image from T&E
A recent report by Transport and Environment outlines that the industry should aim to recycle up to 90% of lithium and 98% of cobalt, nickel, and copper from EV batteries. This process would prevent the need for further extraction of these vital materials from the earth, significantly reducing the environmental footprint of battery production. Car manufacturers are already introducing innovative methods to recycle and repurpose batteries, as seen with Volkswagen’s first pilot plant for battery recycling, where batteries are assessed to either be fully recycled or given a second life.
Step-by-Step Breakdown of the EV Battery Recycling Process
The recycling of electric vehicle batteries involves several key steps to ensure that valuable materials are recovered and waste is minimized:
Collection and Sorting
First, old or discarded EV batteries are collected from car manufacturers, dealerships, or end-users. Once collected, the batteries are sorted based on their type, size, and condition.
Discharge and Dismantling
Before any recycling begins, the batteries are carefully discharged to ensure there is no residual energy left inside. This is a crucial step, as active batteries can be dangerous to handle. Once discharged, the batteries are dismantled, and shredded to access the materials inside.
Separation of Materials
The shredded materials are then sorted using a variety of mechanical and chemical techniques. The goal is to separate the valuable metals and components (such as lithium, cobalt, nickel, and copper) from non-recyclable parts like plastic and paper.
Purification and Refining
After separation, the valuable materials are purified and refined to a level where they can be reused in the production of new batteries or other products. This step is crucial for ensuring that the materials are of high enough quality to be reintroduced into the supply chain.
Repurposing or Disposal of Non-Recoverable Materials
Any remaining materials that cannot be recovered or reused are safely disposed of or processed further. The goal is to minimize landfill waste and ensure that as much of the battery as possible is repurposed.
There are two primary methods used for extracting valuable metals from EV batteries: pyrometallurgy and hydrometallurgy. Both methods have their advantages and limitations, but they differ significantly in terms of process and environmental impact.
Pyrometallurgy (High-Temperature Process)
Pyrometallurgy involves heating the battery materials to extremely high temperatures to melt the metals and separate them from the rest of the battery components. This is a more traditional recycling method that has been used for many years in the metal industry.
Pros: It is effective at recovering metals like copper, nickel, and cobalt. The process is relatively straightforward and can handle a variety of materials.
Cons: It’s an energy-intensive process that generates a lot of heat, resulting in high carbon emissions. Additionally, pyrometallurgy is less effective at recovering lithium, making it a less suitable method for recycling EV batteries.
Hydrometallurgy (Water-Based Process)
Hydrometallurgy uses aqueous solutions to extract metals from battery materials. This method involves soaking the shredded battery materials in a liquid solution to dissolve the metals, followed by a series of chemical reactions to isolate and purify the metals.
Pros: Hydrometallurgy is more efficient at recovering lithium and other critical materials like cobalt and nickel. It’s also less energy-intensive compared to pyrometallurgy, making it more environmentally friendly in the long run.
Cons: It can take longer to complete and requires the use of chemicals that need to be carefully managed to avoid environmental contamination.
Recycling EV batteries offers significant economic value by reducing the need for new mining operations, which can be costly and environmentally damaging. The value of the metals recovered from a single EV battery can be substantial with the average values for end of life BEV battery packs being around £1200 in 2018.
Image from HVM.Catapult
At present, the recycling rates for lithium-ion batteries are improving, but there is still a long way to go. According to the European Battery Alliance, about 5% of lithium-ion batteries are currently being recycled into new batteries. However, when it comes to cobalt, nickel, and copper, the recycling rate is significantly higher, with around 50-60% of these materials being successfully recovered and reused.
The overall target for EV battery recycling is to increase these rates substantially. The European Union and United Kingdom are actively pushing for more efficient recycling processes, and many automakers are investing in advanced recycling technologies to improve these numbers.
Sometimes a battery is given a second life: Sustainable power solutions
When an electric vehicle (EV) battery drops to about 30% of its capacity, it’s no longer efficient for driving but still has plenty of life left for other uses. Instead of discarding these batteries, many automakers are repurposing them for energy storage and commercial applications, contributing to a more sustainable energy future.
Image from Wikipedia
Energy Storage for Homes
Second-life EV batteries are an affordable solution for home energy storage, especially for homes with solar panels. By storing excess solar energy, homeowners can use it when the sun isn't shining, making energy usage more independent and sustainable.
For example, BMW and Sonnen have partnered to offer affordable home energy storage systems using repurposed EV batteries, making solar energy more accessible.
Commercial Uses for Old Batteries
Nissan: Backup Power for Amsterdam Arena
Nissan repurposes Leaf EV batteries for backup power at the Amsterdam Arena, proving how second-life batteries can help businesses secure affordable and reliable energy.
Toyota: Solar Storage in Japan
Toyota will use discarded batteries outside convenience stores to store solar energy, powering appliances like fridges and food warmers, helping businesses lower energy costs and carbon footprints.
Renault: Stationary Storage Facility
Renault is creating a stationary electricity storage facility using Zoe EV batteries, demonstrating how second-life batteries can support grid stability and even power boats.
Grid Storage & Cost Savings
Second-life batteries are also being tested for grid-scale energy storage, where they help balance supply and demand by storing excess energy during off-peak times. Projects in the UK and EU are using these batteries to stabilize grids and support renewable energy adoption.
Repurposing EV batteries for energy storage offers significant cost savings, as second-life batteries are much cheaper than new storage systems. For businesses, this translates into lower energy bills and reduced reliance on the grid.
With all the ongoing developments around second lives for electric car batteries, it is safe to say that their lifespan doesn't stop at powering your car. They will outlive it and help the environment another way!
UK Infrastructure & Future
Image from Wikipedia
The UK is developing infrastructure to recycle electric vehicle batteries and establish a domestic supply chain. The government is funding research and development projects, and companies are building new facilities - helping to make EVs and their batteries sustainable and useful in the long-term.
Government support and Company-led initiatives
There are several efforts being made on both the government, and company level to recycle EV batteries, and improve manufacturing supply chains. The UK has also adopted the EU End of Life Vehicle Directive - meaning that UK manufacturers must meet new targets for recycled materials within their batteries - amongst other things.
The UK Governments Critical Minerals Strategy is in place to support the UK's position in battery recycling, with initiatives like The Faraday Battery Challenge which is aimed at commercialising battery recycling technologies.
There is also funding for research and development, with projects like RECOVAS and ReLiB focussing on the circular supply chain for EV batteries in the UK.
Companies like Veolia and Technology Minerals are tackling the challenge from a commercial perspective - with a facility in the Midlands to dismantle EV batteries for recycling. There are other facilities in Wolverhampton, and Warrington - among others.
Innovate UK has estimated that 150,000 tonnes of waste will need to be recycled each year by 2035, with battery cells using nickel or cobalt generally containing around £7/kg of value. This creates enormous potential for both UK recyclers through raw material value, and end-users through second-hand battery repurposement. To facilitate this influx, UK manufacturers must meet new targets for recycled content in their batteries - with at least 16% cobalt, 6% lithium and 6% nickel that comes from recycling, with these percentages rising to 26%, 12% and 15% respectively by 2036.
Future Potential
Aside from recycling, battery technology is also set to continue improving - increasing lifespan, efficiency, and energy density - thus reducing the volume of waste.
New materials are being trialled, such as Lithium Sulfur (Li-S) chemistries from OXIS Energy - aimed at increasing the energy density, which will reduce the quantity of material needed, whilst improving EV range. Latest tests showed that energy densities of 400Wh/kg are possible - improving on current EV batteries that achieve 200-300Wh/kg. New BATSEED is another project working to do the same.
On the other end of the spectrum, developments in low-impedance cell technology could lead to faster charging - as is being trialled at Nyobolt. The aim is to produce EV batteries capable of super-fast charging without degradation - unlocking petrol-like refuelling times, whilst reducing waste as a result of fewer end-of-life batteries.
Important things to consider as an EV driver
There are a few factors that can influence EV battery life - and it is important to understand them as a driver. Luckily, most of these factors are mitigated by the car itself through automatic battery management.
Image from Gaurav Ahluwalia
Temperature
Both extreme heat and cold can shorten the life of an EV battery. In practice, you may see slightly reduced range during temperature swings as electric cars will pre-condition themselves to maintain optimum battery temperature through cooling or heating. Air conditioning or heating the cabin will also impact range in much the same way as it does in combustion engine vehicles.
If charging at home, you may find it beneficial to keep the car plugged in when not in use as the car will continually draw some power from its battery (although this is minor).
Charging habits
Keeping the battery between 20-80% is the best way to prolong its life. Charging from 20% to 80% is also the fastest part of the charging cycle, due to battery chemistry. Charging all the way to 100% will not only slow down the overall charge time, but can degrade the battery - especially at higher charging rates (think fast chargers).
Frequent use of fast chargers can increase the battery's temperature, which can also degrade its lifespan. Ultimately, the more times the battery is charged, the less efficient it becomes.
Driving Habits
Hard acceleration drains the battery more quickly, whereas using a softer, more gradual acceleration can help extend the range. In the same vein, harsh braking, or late braking is also less efficient than anticipating and slowing down in good time. Using regenerative braking slow down will store energy in the battery and can extend the range.
Driving at higher speeds requires more power from the battery, which reduces the range, however adjusting your speed to the distance to the next charging point can help extend the range - as the battery will drain slower at lower speeds.
Warranties and battery lifespan
Is it worth worrying about battery degradation day-to-day? For most drivers of most EVs - probably not. An electric vehicle battery warranty covers the cost of repairs or replacements for a set period of time or distance. These warranties typically cover around 8 years or 100,000 miles of driving.
The warranty usually guarantees that the battery will maintain at least a certain level of charging capacity, typically around 70%. If the battery's capacity falls below the set level, the manufacturer will repair or replace it, if it is within the warranty. Even after the warranty, many older or high-mileage EVs can still run and hold a decent charge.
For context, a 250 mile range EV will still have 175 miles of range, if it has degraded to 70% of its original capacity after 100,000 miles.
When buying an EV, check the terms and conditions of the warranty and consider the condition of the battery, when buying a used car. Check that the warranty transfers to the next owner.
You can typically spot signs of battery degradation by reduced range, slower charging times, or simply a warning light on the dash. It is worth noting, however, that this is only likely to occur in much older vehicles.
How can I get my hands on an electric car?
The Electric Car Scheme makes switching to an electric car more affordable through salary sacrifice. Instead of paying with post-tax income, the monthly payments are deducted before tax and National Insurance, saving you 20-50%.
Use our salary sacrifice car calculator to explore the latest electric cars and see your potential savings.
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