Recycling e-vehicle batteries: A solution for the future

“We have an ethical obligation to get as much use out of batteries as possible, and once they are worn out, we should recycle the raw materials,” says Rúnar Unnþórsson, professor of engineering at the University of Iceland. He is now working on a fascinating study looking at battery recycling and, together with his students and in close collaboration with the startup company Alor, exploring how used EV (electric vehicle) batteries can be given a new purpose. 

This includes batteries from vehicles that have been in collisions, as well as batteries that have stopped working due to age or even been recalled from manufacturers. EV batteries in Iceland are expected to last around 12-15 years. However, this depends on several factors, including usage, charging, discharging, and quality.

“The idea we are working on is taking the EV batteries apart.  These batteries are made up of many small cells.  We can measure the cells to determine their condition. We can then group together the cells that are in a similar condition, i.e. filter out the ones in poor condition and use the ones in good condition to make new batteries.”

Could help ensure energy security

The batteries created from recycled cells could be used for “stationary energy storage systems”, according to Rúnar. Generally, other kinds of batteries – usually cheaper kinds – have been used for these purposes.  This is because stationary batteries do not need to meet the same requirements with regard to weight and power. EV batteries are designed to be as light as possible, with the shortest possible charging time and maximum power. 

Stationary energy storage systems are used to store electricity, providing a secure backup in the case of a power outage and for handling spikes in energy demand. Energy security is extremely important, particularly for essential infrastructure, such as in hospitals, computer labs or even automatic milking machines on farms.

Many challenges involved in recycling batteries

“There are a lot of exciting engineering challenges in designing battery packs, whether they are constructed from new or used cells,” says Rúnar. One of the challenges is that EV manufacturers use different types of cells, which can complicate the process of evaluating their condition and combining them into a single solution.

It can also be challenging to analyse the properties of a battery, and things are always more complicated than they first appear. “The properties of cells vary. They might have different voltages or provide different levels of current – there are many factors to consider. Even once you’ve identified some cells that are in good condition, you then face the challenge of finding a way to utilize them to create a new battery that meets all the required standards regarding function and safety,” says Rúnar.

New specialised facilities are currently being developed at UI for testing batteries. Once these facilities are in place, the research team will be better equipped to evaluate the condition of cells and develop solutions in a safer and more systematic manner. 

A problem crying out for a solution

This project is connected to other projects Rúnar has been working on, all of which explore the topic of underutilized resources. For example, Rúnar has been working on projects that focus on using organic waste to generate thermal energy and electricity and using waste heat to produce electricity and also to grow plants.  The idea of working with used EV batteries came to Rúnar after he heard about the problem of what we should do with these batteries once they can no longer be used in EVs. This is a problem crying out for a solution. He points out that disposing of EV batteries is a huge issue – they pile up at auto salvage yards and there is a real lack of sensible solutions for dealing with them.

Rúnar adds that the production of raw materials for batteries is a ‘dirty’ industry, to say the least. It requires a lot of mining (e.g. for nickel and cobalt), which causes significant pollution and has a serious detrimental impact on workers and local communities. The industry also involves a lot of other unethical practices, such as child slavery and poor working conditions. By reusing batteries and extending their lifespans after they can no longer be used in an EV, we can reduce the demand for new batteries. And once a battery cannot be used at all any more, we can recycle the metals, reducing the need for mining operations. 

Iceland in an ideal position to lead the way

Rúnar believes that Iceland, with its renewable energy resources, is in an ideal position to lead the way in developing better solutions for getting more use out of batteries. He is confident that new and exciting ideas will emerge as we gain a deeper understanding of battery technology here in Iceland.

Rúnar says that, thanks to grants from the former Minister of the Environment, Guðlaugur Þór Þórðarson, and other partners, the UI research team has been able to invest in high-tech equipment for evaluating the condition of batteries and their potential uses.

He hopes that the study will help uncover new solutions for tackling environmental challenges and ensuring energy security. “We can make better use of the resources we have and this means we can reduce the demand for new raw materials, as well as the negative environmental impact it costs to acquire them,” he explains.

Recycling electric vehicle (EV) batteries is a crucial step towards achieving sustainability and protecting the environment. By developing technological solutions that make recycling commercially viable, we can reduce waste, get more use out of resources and promote a greener future. This study by Rúnar Unnþórsson and his students shows that just because a battery can no longer power an EV, this doesn’t have to spell the end of its lifespan. Rather, it marks the beginning it is the start of a whole new world of possibilities.