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4.4 Costs of EV Battery Reuse The US Department of Energy (DOE)'s Vehicle Technologies Office funded the National Renewable Energy Laboratory (NREL) to develop a model to calculate costs of EV battery reuse – the B2U Repurposing Cost Calculator79, which was released in June, 2015. The Excel workbook cost model allows businesses to determine capital, labour and other business costs and profitability from refurbishing PHEV batteries. While the research was carried out on PHEV rather than BEV batteries, the conclusions are likely applicable to BEV batteries as the same battery chemistries are used, but the PHEV batteries are smaller. The main assumptions in the model are: • Batteries would be collected from a catchment area within a round trip of 320 miles from the facility (8-hour round trip for collection); • The facility would have a throughput of 1 million kWh each year; • It would process 547 modules/day (200,000 modules/year); • Capital costs are $15 million for a 15,000 sq. ft. building; • Labour, testing and material costs were estimated for a battery pack with a nameplate capacity of 5kWh; a nameplate energy density of 150Wh/L; nameplate specific energy of 115Wh/kg; and a mass of 43.5kg with remaining capacity of 3.5kWh at the time of repurposing; and • The facility has 83 employees and 199 technicians. The NREL study for which the model was constructed stated that PHEV batteries can be repurposed for as little as $20/kWh or $500 per battery. The model details include repurposing costs of $24/kWh and battery purchase costs of $20/kWh for a total reuse cost of $44/kWh. This can be compared to new battery purchase costs of about $350/kWh at the time the analysis was carried out. A 2017 Bloomberg report states the price of a li-ion battery in 2014 was $540/kWh and in 2015 was $350/kWh. By 2016 this had declined to $273/kWh. Industry representatives interviewed for this study felt that the dynamics of the EV battery reuse market would change when the cost of new EV batteries fell to $100/kWh. There are differing predictions on when this might happen. Bloomberg data presented in Section 7 shows that the cost of new EV batteries is projected to be about $94/kWh in 2024 and $62/kWh by 2030. Meanwhile Lei Zhang, founder of Envision Energy, expects the cost of manufacturing EV battery cells to fall below $100/kWh by 2020.80 The same article also states that Arun Majumdar of Stanford predicts that sub-$100/kWh prices are unlikely to occur for five to seven years (2023 to 2025). The NREL analysis and other information reviewed for this study show a clear case for maximizing the reuse of EV batteries given the positive economics o f t h i s o p t i o n compared to recycling 79 NREL. “Battery Second Use for Plug-in Electric Vehicles.”PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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