New life for discarded lithium-ion batteries
Prototype battery management systems and a selection of extracted and tested cells. Product |
Second life lithium-ion (Li-ion) battery management system (prototype). |
Material classification |
18650 Li-ion cells. |
Product specifications and standards |
18650 mixed capacity battery management system. |
Project type |
Research, development and validation. |
Research result |
The research demonstrated that 59.41% of the discarded Li-ion cells extracted retained over 80% of their original capacity. The potential for safe reuse in new applications was validated with a specially designed battery management system (BMS) prototype. |
Sector |
e-waste processing. |
Grant recipient |
Sequence Digital Pty Ltd |
SV funding |
$46,200 |
The outcome
The Sequence Digital project team found there is great potential to reuse discarded lithium-ion (Li-ion) cells in applications with less demanding energy needs.
Their battery management system (BMS) prototype proved able to manage and monitor individual cells from different manufacturers with varying capacities. It enabled each cell to operate optimally within its own charge and discharge limits. A system for reuse of cells is possible, provided precautions are taken.
The project team also investigated regulatory requirements for products in Australia containing Li-ion. They identified potential pathways for the safe and compliant reuse of Li-ion cells.
The need
According to the CSIRO, ‘Only 10% of Australia's lithium-ion battery waste was recycled in 2021, compared with 99% of lead acid battery waste. Lithium-ion battery waste is growing by 20% per year and could exceed 136,000 tonnes by 2036’.
Electronic waste (e-waste) is fast becoming one of Australia’s largest waste streams. Li-ion battery waste poses growing environmental and logistical challenges. These batteries are in:
- smart phones
- electric vehicles
- a huge range of appliances.
Discarded batteries pose risks of:
- contamination
- fire hazards
- resource wastage.
Often, they are discarded with cells that are still usable. There is a need to extend their life through re-use and building the capability to recycle them at the end of their useable life.
'There's a significant and growing amount of lithium-ion battery waste, and the CSIRO has highlighted the lack of viable disposal options here in Australia. Our research demonstrates that, with the right precautions, up to 59% of discarded lithium-ion cells from small cordless appliances could be reused elsewhere before recycling.'
A collection of discarded battery packs from the Geelong Resource Recovery Centre and Transfer Station. Developing the solution
The project team explored the volume of discarded battery packs containing cells that are still useable. They investigated the technical feasibility of safely reusing those cells in new applications.
They also needed to test the regulatory pathways for such an application. They developed a prototype BMS capable of handling mixed-capacity cells. This aimed to show that it is possible to delay the end-of-life disposal and recycling stage of serviceable cells. Reuse can extend the life of valuable resources. This reduces waste and supports the transition to a circular economy.
Fifty discarded battery packs were disassembled and tested to assess the viability of reusing cells. This involved:
- collecting battery packs from a local resource recovery centre (excluding damaged packs)
- developing procedures for safe handling and cell extraction
- evaluating pack design for ease of disassembly, and testing of cells capacity
- analysing data obtained to determine the reuse potential of the cells.
The project team developed a BMS prototype to manage and track individual cells was developed. It can isolate cells, prevent over-charge/discharge, and track temperature. Prototyping involved testing and refinement.
The partnership
The City of Greater Geelong provided support with battery pack collection and device demonstration. The Geelong Resource Recovery Centre and Transfer Station provided post-consumer waste.
The BMS prototype is on display at the City of Greater Geelong's Garden Organics Processing Facility.
'Reuse, before recycling, is a major component of circular economy principles - all the work and pollution associated with mining, refining, processing and manufacturing a product is already done. In developing a prototype battery management system capable of managing mixed-capacity cells, we have laid the groundwork for new markets in safe battery reuse. We're thrilled to contribute to product reuse.'
Pathway to commercialisation
The project provides a pathway for reuse of Li-ion batteries.
It could open new markets for battery recyclers and stewardship programs. It would also reduce dependence on raw materials.
The project’s insights support policy aimed at improving battery recycling and reuse infrastructure. There is potential to offer the end-user a choice of more sustainable ways to power devices.
The City of Greater Geelong have awarded Sequence Digital funding to further develop the prototype and take it through regulatory testing.
For more information, please read the full case study and dataset.