Second life use of Li-ion batteries in the heavy-duty vehicle industry: Feasibilities of remanufacturing, repurposing, and reusing approaches

As the adoption of electric vehicles (EVs) accelerates, the efficient management of end-of-life lithium-ion (Li-ion) batteries becomes a pressing concern. This case study investigates sustainable second life approaches for Li-ion batteries within a leading manufacturing company in the heavy-duty vehicle industry. Employing an exploratory methodology, the study evaluates three distinct circularity approaches for second life applications: remanufacturing, repurposing, and reusing. Based on a financial model and sustainability metrics, remanufacturing emerged as the most economically viable and environmentally sustainable strategy for the company. The study also explores supplementary approaches, such as repurposing used batteries for smaller power applications and reusing them in large-scale Energy Storage Systems (ESS). Regulatory inconsistencies in battery second life are identified as a significant barrier to widespread implementation. The study concludes by advocating for a multi-stakeholder ecosystem approach and calls for the establishment of universal circularity regulations to streamline the second life of Li-ion batteries.