The Battery Recycling Dilemma: EV Battery Lifespan

Let’s talk about one of the big controversies around EVs. The batteries. Not only are there ethical issues surrounding the sourcing of the lithium, cobalt, and nickel in these batteries, but they also don’t last forever. And when they start to fade, what happens next? That’s the dilemma we’re facing—what to do with these massive batteries once their time’s up, and how recycling fits into the picture.

Electric Vehicle Battery Lifespan: How Long Do They Really Last?

Most EV batteries, specifically Lithium-Ion batteries with the highest energy density for a reasonable price, are built to last. On average, they’ll last anywhere from 10 to 20 years. That’s a solid run. Most car manufacturers even guarantee the battery for about 8 years or 100,000 miles, but many last much longer with proper care. But, over time, the battery’s performance starts going downhill, like anything else. You might start to notice your car’s range isn’t what it used to be. It’s not dead, but it’s not quite as vigorous as it was on day one.

For example, one Tesla Model S owner charged their vehicle daily, mostly at home using a 25-amp charger to 90% State of Charge (SoC). Despite racking up 102,000 miles, their car’s range dipped by just 6% over nine years—from 264 miles (425 km) initially to around 248–250 miles (400 km). Another Model S owner with 220,000 miles on the odometer reported 18% degradation, retaining 82% battery capacity even after ten years. Most users in similar use-case scenarios reported degradation between 6% and 13% over several years, which is impressive for a battery expected to last over a decade .

What Happens to EV Batteries After Use?

Just because your EV battery isn’t cutting it for your car anymore doesn’t mean it becomes waste immediately. Most batteries retain close to 90% of their charge capacity after ten years. This means they’re still quite capable and can serve a second life, often as energy storage for homes or businesses. Of course, even these second-life uses have an expiration date and will eventually degrade to the point where recycling becomes necessary.

The Challenge: EV Battery Recycling

Now, this is where things get interesting. EV batteries are packed with valuable materials—the lithium, cobalt, nickel we mentioned—and it’s challenging to extract these materials once the battery expires. Recycling these materials effectively and sustainably is not easy. Current methods, primarily smelting and chemical processes, are costly and can negatively impact the environment if not handled properly.

However, there’s hope in this area. Tesla, for instance, has developed a recycling process for its batteries, achieving almost 92% reuse of raw materials. This innovation aims to create a closed-loop system where old batteries are recycled into new ones, reducing mining demand and making the entire process far more sustainable.

Our Role: Recycling Old Batteries and Cars

Let’s talk about EV conversions. EV conversions give used EV batteries a second life in the body of an old car. However, we need to clarify that EV conversion batteries are typically sourced from vehicles with under 30,000 miles—often salvaged from wrecked cars where the battery pack is in excellent shape. Batteries with fewer miles obviously keep higher charging capacity, making them ideal for conversion projects. The more miles on a battery, the lower its capacity and the cheaper it is, which is why mileage is a critical factor in sourcing batteries for conversions.

These batteries, often with most of their capacity intact, are repurposed to electrify classic gas vehicles. Not only does this save these batteries from an early trip to the grave, but it also keeps older cars on the road in a greener way, compounding your positive environmental impact. It’s a smart, sustainable fix that’s beneficial for car enthusiasts and the planet alike.

As more people adopt EVs, the need to manage used batteries responsibly is growing. Specialized laboratories now recycle, test, and repair used batteries for a second life in the EV conversion industry. And while today’s solutions are promising, the hard part lies in handling batteries 10-20 years down the line, once they are fully expired. Fortunately, the industry is committed to meeting this challenge head-on, paving the way toward a more sustainable future.