Presentation Closing the loop: Disassembly, Testing, Remanufacturing, Second Life and Recycling by Envirobat & CSIC during the last Exploitation Webinar held on 25th November 2021

1. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851

2. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Closing the loop: E&HEV batteries
disassembly, testing, remanufacturing,
second life and recycling
25th November 2021

3. End of Life Battery: POSSIBLE PATHS
EV
BATTERY
Re-use
Repair
Recycling
2nd Life
(Repurpose)
End of first life
(application for which it was
originally manufactured)
Start of 2nd life
(application for which it was not
originally manufactured)
European regulation to address difference:

4. Second Life Battery to APPLICATIONS
2nd LIFE
BATTERY
Dismantling
2nd LIFE
APPLICATION
Application Requirements
Testing
Remanufacturing
2nd life battery
module
Recycling

5. Disassemble – Module to Cell
GENERAL PROTOCOL
Dismantling
SOS- standard operational
sheets

6. Battery Testing Testing
For a video on the battery testing performed by JRC click here

7. Battery Testing
Battery Cell Renegade EIG GS Yuasa
EV environment Jeep Renegade Mitshubishi Outlander
Model type LG Chem P33 ePLB C (C020) LEV40
Cell type
Prismatic laminated
package
Pouch Hard-case prismatic
Chemistry
(cathode/anode)
Li-ion polymer
(NMC/Graphite)
Li-ion polymer
(NMC/Graphite)
LMO-NMC/Graphite
Testing
• Cell connection to the instrument needs careful
analysis to ensure repeatable & reproducible results
• Damaged tabs can negatively impact the testing

8. Equipments Model/type Experiments undertaken
Battery cycler
Maccor multifunction Series 4000
bidirectional battery tester
Galvanostatic charge/discharge cycling
Self-discharge
Environmental chambers
- BiA MTH 4.46
- Vötsch VCS3 7060-5
Temperature control and monitoring
Testing
• Temperature controlled environment
Battery Testing

9. Equipments Model/type Experiments undertaken
Battery cycler
Maccor multifunction Series 4000 bidirectional
battery tester
Galvanostatic charge/discharge cycling
Self-discharge
Environmental
chambers
- BiA MTH 4.46
- Vötsch VCS3 7060-5
Temperature control and monitoring
Impedance tester
ModuLab XM (Solartron Analytical, AMETEK
Advanced Measurement Technology)
Electrochemical Impedance
Spectroscopy analysis (EIS)
Battery test Hioki BT3562
OCV (Open Circuit Voltage)
Internal resistance (4-terminal AC
method)
Testing
Battery Testing
Few minutes Few seconds

10. a) PRE-TEST: GATHERING OF DOCUMENTATION
b) SAFETY-ORIENTED TESTS: b.1) Visual Inspection
c) PERFORMANCE-ORIENTED TESTS
c.1) Open Circuit Voltage (OCV)
c.2) Refresh Cycles
c.3) Residual Capacity (e.g. 1C)
c.4) Internal Resistance (AC method and electrochemical Impedance Spectroscopy)
c.6) Self-discharge (times: 5 min, 60 min, 24 h)
Standard PROTOCOL
Testing
Battery Testing

11. INDUSTRIAL PROTOCOL
Testing

12. 2nd Life Battery Applications
Producer
looking for 2nd life
batteries
Remanufacturer
looking for 2nd life
application
USUAL PROCESS
NEW PARADIGM
Remanufacturing

13. Considerations for 2nd Life Batteries:
2nd life Applications
Electrical
properties
Physical
characteristics
Safety & Control
External
protection
Voltage
Power
Size Mobility
Casing
Weight Thermal control
Mobility Power Electronics
Depending on the SIZE of the 2nd Life Application:
SMALL
SCALE
Ventilator
LARGE
SCALE
Stationary storage system
Remanufacturing

14. DEVICE POWERED:
23 streetlights
ELECTRICAL REQUIREMENTS:
400 V AC
Up to 18 h autonomy
3 days in a row
APPLICATION:
Cycle path illumination in
Los Navalucillos (Toledo)
LARGE SCALE: Street lighting
stationary storage system
Remanufacturing

15. REQUIRED COMPONENTS:
• PV panels
• 2nd Life modules from EV
• AC/DC inverter
• Battery Management System
• Refrigeration system (fans)
• Module to BMS interface board
• Contactors, fuses and current sensors
Configuration 9s4p
(36 modules)
4 BMS
(1 master, 3 slaves)
Fans
(controlled by BMS)
Contactors, fuses and
current sensors
Module to BMS
interface board (x36)
Inverter
PV panels (x20)
LARGE SCALE: Street lighting
stationary storage system
Remanufacturing

16. SMALL SCALE: Ventilator
DEVICE POWERED:
Simple and low cost ventilator, RESPIREM, for
COVID-19 and other diseases
ELECTRICAL REQUIREMENTS:
12 V DC, 5 A
APPLICATION:
Electric back-up in case of power supply cut.
Portable power supply in emergencies and field hospitals.
Remanufacturing

17. SMALL SCALE: Other examples
Vacuum pump
Sonar
device
Cool box
Remanufacturing

18. Recycling
Collect the
damaged and NOT
REUSABLE
BATTERIES from
disassembly
activities
PREPARE the
wasted samples,
discharging and
evaporating the
electrolyte for a
safe process
RUN THE
MECHANICAL
TREATMENT with
the optimized
operating
parameters
Use the
EXTRACTED BLACK
MASS in the
subsequent
recycling process
to recover
valuable metals
Segregation of active black mass
MECHANICAL PRE-TREATMENT
Black mass
recycling process
INPUT
OUTPUT
Disassembly and
testing
Mechanical pre-treatment

19. Recycling
Mechanical pre-treatment
PERFORATION
to evaporate the
gaseous electrolyte
CUTTING
for feeding constraints
of cutting mill
GRINDING
2-4 mm grid, 3000
RPM, cyclone system
SIEVING
200, 400, 700 and 1000
µm sieves
Safety and technical preparing steps
before the grinding
Mechanical process for the segregation of
black mass

20. Recycling
For a video on Batteries Recycling Solutions performed by CSIC click here

21. Conclusion
Disassembling
Improved safety and time(cost)
through automatization
Testing
Standardized and adapted for
industrial needs
2nd life
Feasible and Competitive
Recycling
Technically feasible

22. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Thanks for your attention!!
25th November 2021

23. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851

24. Annex – additional data
a) b)
Figure 1. Picture visual inspection of faulty battery a) (Renegade type) compared to a b) intact battery cell

25. Annex – additional data
Figure 1. OCV upon arrival for each battery cell (with comparative to their expected
minimum- maximum admissible voltage range; a) Renegade cells, b) EIG
cells, c) LEV cells

26. Figure 1. Internal resistance values upon arrival (AC method) for each battery cell
Annex – additional data

27. Figure 1. Electrochemical impedance spectra for Renegade cells, effect of the SoC
Annex – additional data

28. Figure 1. Electrochemical impedance spectra for EIG cells, cell to cell variability
Annex – additional data

29. Figure 1. Electrochemical impedance spectra for Renegade cells, cell to cell variability
Annex – additional data