EV batteries remanufacturing : BORG automotive challenge - Team 33

Mahmood, Khalid and Gutteridge, Fiona (2019) EV batteries remanufacturing : BORG automotive challenge - Team 33. In: Reman Challenge BORG June 2019, 2019-06-23 - 2019-06-25.

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European aspiration is to achieve a 100 percent Electric Vehicle (EV) sales target by 2030, which brings new business opportunities for the automotive remanufacturers to get involved in EV batteries remanufacturing. This involves overcoming the current weakness in the EU automotive market position for the Hybrid and Electric Vehicle batteries remanufacturing as well as after sales support and manufacturing. Almost all major automotive manufacturers have already produced a Hybrid or fully Electric car model. However, the price of the car is still expensive due to the Lithium-ion Battery cost. This paper reviews the evolution of the Lithium-ion Batteries design changes in the production and remanufacturing opportunities as well as anticipated changes in cost due to manufacturing. Europe has the biggest market share of the EV, which is set to grow further substantially. The following aspects which are relevant to the EV battery components are covered in this review; •Technical Analysis of EVs end-of-life Lithium-ion (Li) Batteries for the reuse, recycling, remanufacturing options provide growth opportunities for Independent Remanufacturers (BORG Automotive) in Europe. •Battery efficiency – 90% efficiency is seen in the EV Battery Cells after 10 years old Electric cars; because EV batteries come with a15-year life cycle, so that the Li Batteries can be reused and remanufactured for the 2nd life cycle, as required. •A high-level review of environmental Impact and benefits of remanufacturing EV Batteries and contribution to energy and carbon reduction. •Innovative E-Mobility Infrastructure in Europe, review of EV’s chargers’ points, EV Charging Timeline, and Remanufacturing Li Batteries Challenges. EV battery remanufacturing provides tremendous untapped benefit and opportunities in the European markets. The automotive sector is the most beneficial area from remanufacturing and which accounts for 70% of all remanufacturing companies across the globe. To be able to access this new market BORG Automotive must build up new reverse engineering knowledge for Electric Vehicles and Li Battery Packs to find a suitable methodology which helps them to develop new test stations and jigs based on new technologies for auto fault diagnostic testing and resetting of Electronic Unit boxes according to the Original Equipment Manufacturer (OEM) test specifications. The increasing market demand for the Lithium-ion traction batteries implies the need to recover active materials from spent Li Batteries, as well as from the electrodes from the OEM production batch rejects to prevent future shortages. This would minimise the dependence on imported key raw materials for Li Batteries, because 75% of the cost of an electric vehicle is the Li battery system, which is determined by the battery cell investment and the proportion of an active materials is in high volumes compared to consumer electronic products which use Li batteries such as Laptops or Phones. Two different end applications and products are recommended in this report, first one is the reuse of Li Batteries in the EVs and second is recycle of Li Batteries to make a Power Bank and third application is the recovery of raw materials from battery Cells.