The increasing demand for Lithium-ion batteries for Electric Vehicle calls for the adoption of sustainable practices and a switch towards a circular economy-based system to ensure that the electrification of transportation does not come at a high environmental cost. While driving patterns have not changed much over the years, the current Electric Vehicle market is evolving towards models with higher battery capacities. In addition, these batteries are considered to reach the End of Life at 70-80% State of Health, regardless of their capacity and application requirements. These issues may cause an underuse of the batteries and, therefore, hinder the sustainability of the Electric Vehicle. The goal of this study is to review and compare the circular processes available around Electric Vehicle batteries. The review highlights the importance of prioritizing the first-life of the battery onboard, starting with reducing the nominal capacity of the models. In cases where the battery is in risk of reaching the End of Life with additional value, Vehicle to Grid is encouraged over the deployment of second-life applications, which are being strongly promoted through institutional fundings in Europe. As a result of the identified research gaps, the methodological framework for the estimation of a functional End of Life is proposed, which constitutes a valuable tool for sustainable decision-making and allows to identify a more accurate End of Life, rather than considering the fixed threshold assumed in the literature.

Using batteries after their first life in an Electric Vehicle (EV) represents an opportunity to reduce the environmental impact and increase the economic benefits before recycling the battery. Many different second life applications have been proposed, each with multiple criteria that have to be taken into consideration when deciding the most suitable course of action. In this article, a battery assessment procedure is proposed that consolidates and expands upon the approaches in the literature, and facilitates the decision-making process for a battery after it has reached the end of its first life. The procedure is composed of three stages, including an evaluation of the state of the battery, an evaluation of the technical viability and an economic evaluation. Options for battery configurations are explored (pack direct use, stack of battery packs, module direct use, pack refurbish with modules, pack refurbish with cells). By comparing these configurations with the technical requirements for second life applications, a reader can rapidly understand the tradeoffs and practical strategies for how best to implement second life batteries for their specific application. Lastly, an economic evaluation process is developed to determine the cost of implementing various second life battery configurations and the revenue for different end use applications. An example of the battery assessment procedure is included to demonstrate how it could be carried out.

Presently, Electric Vehicle batteries are considered to have reached the End of Life once their State of Health falls to 70-80%. However, this criteria is universal to all battery capacities and not based on the specific application requirements. To evaluate whether the End of Life can be extended below the current threshold, the impact of the Internal Resistance increase needs to be addressed. In this sense, this study employs a degradation aware electrothermal model to evaluate the battery performance for different use cases. The findings reveal that capacity constraints are the main cause of the End of Life, followed by power constraints. However, this is highly dependent on the battery capacity. Large capacity batteries tend to reach the End of Life for capacity constraints, whereas smaller ones show power limitations first. The temperature increase has not shown to be a restriction for any of the cases simulated. The decline in performance is for most cases (37.5% of the simulated ones) noticed below 70% State of Health, supporting that the first-life of most batteries can be extended without compromising the vehicle's performance. This is especially the case for most average drivers using large battery capacities, currently emerging on the market. The methodology proposed for the simulated cases can be extended to real time operation in the Battery Management System. Estimating the End of Life in this way can support the maximization of the first-life and only requires an appropriate use of the available data.

Second-life businesses from Electric Vehicle (EV) batteries are gaining attention considering that these batteries are deemed as inappropriate for transport purposes once they reach 80 or 70% of State of Health (SoH). However, the limited number of retired batteries and the trend in battery capacity increase hinder a realistic evaluation of second-life applications. To analyze battery reuse, a closer look at the End of Life (EoL) conditions of these batteries must be taken. This study presents a battery ageing model to estimate the SoH of EV batteries according to their age and mileage. The model is applied to the current retirement characteristics of combustion vehicles to statistically determine the expected SoH at the vehicle EoL. Results indicate that most EVs will reach EoL for reasons other than under-performance. Once retired, most EV batteries will have a SoH higher than 75% within the next 20 years, opening an interesting market for second-life businesses. However, battery reuse is an option that, considering the growing EV market, will rapidly saturate the stationary energy storage demand. Before 2040, most EV batteries will follow streams towards the circular economy, although at some point, they will have to be sent directly to recycling after the vehicular use.

As the Electric Vehicle market grows, understanding the implications of battery degradation on the driving experience is key to fostering trust among users and improving End of Life estimations. This study analyses various road types, charging behaviours and Electric Vehicle models to evaluate the impact of degradation on the performance. Key indicators related to the speed, acceleration, driving times and regenerative capabilities are obtained for different degradation levels to quantify the performance decay. Results show that the impact is highly dependent on the road type and nominal battery capacity. Vehicles with long and medium ranges show a robust performance for common driving conditions. Short-range vehicles perform adequately in urban and rural road conditions, but on highways, speed and acceleration reductions of up to 6.7 km/h and 3.96 (km/h)/s have been observed. The results of this study suggest that degradation should not be a concern for standard driving conditions and mid- and long-range vehicles currently dominate the market. In addition, the results are used to define a functional End of Life criterion based on performance loss, beyond the oversimplified 70–80% State-of-Health threshold, which does not consider individual requirements.