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Rethinking the EV battery journey

Sponsored: EV battery materials are driving cutting-edge innovation and promising a more sustainable future for all.

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Sparta, TN Solar Remanufacturing Plant. Image courtesy of BBB Industries.

This article is sponsored by BBB Industries.

As the world accelerates toward more sustainable transportation solutions, electric vehicles (EVs) are leading the automotive industry. The surge in sale of hybrid vehicles is still outpacing that of EVs. According to Morgan Stanley, U.S. sales of hybrids grew five times faster than EV sales in February. Whether hybrids or EVs take the lead, the quickly evolving landscape still relies heavily on batteries, which require significant mining and refining of materials, and drive cutting-edge innovation. 

While there is a common misconception that the lifespan of EV batteries ends at around 8-10 years, the reality is far more complicated. Through sustainable manufacturing, EV batteries can have a second life in vehicles — or even third life supporting energy storage systems. TERREPOWER, a division of BBB Industries (BBB), is an industry leader and innovator in the sustainable manufacturing of components driving our clean energy and mobility future. It’s playing a crucial role in reducing our environmental impact, shaping a circular economy and providing ecological and cost effective solutions for vehicle owners. 

Once they are no longer able to support a vehicle, EV batteries can be repurposed in various applications such as energy storage in homes and businesses or even in renewable energy systems. This extension of their lifespan both mitigates waste and contributes to a more circular economy — reducing the environmental impact of battery disposal. 

The National Academy of Science and Engineering estimates that the number of used EV batteries available will increase to 150 million in the year 2035. This reinforces the importance of having this infrastructure and established reuse procedures in place.

From raw materials to reliability

EV batteries are created from raw materials mined from the Earth. Lithium, a cornerstone material, nickel and cobalt collectively are integral for battery production. 

Manufacturing batteries involves a series of activities where raw materials are processed to create battery components, which are then assembled into modules to form the battery pack. This pack, once installed in an EV, plays a crucial role in the vehicle power system. It efficiently distributes energy to the drive motors while also maintaining battery health. 

However, today’s batteries may last 12 to 15 years in moderate climates, according to the National Renewable Energy Laboratory. In general, you can expect the lifespan of an EV’s battery pack to be 10 years or 100,000 miles. This longevity is a key factor in the reliability and performance of EVs, making them a good choice for environmentally conscious buyers. 

Breathing new life into EV batteries

After EV batteries reach the end of their first life, they can have a second life in EVs through the sustainable manufacturing process. Remanufacturing, or sustainable manufacturing, is a maximum value retention process, which returns a product to the market at the highest value possible. This is where TERREPOWER comes in to help. 

If the battery is no longer able to support an EV, it can be repurposed, for a third life, to support an energy storage system or renewable energy system. Both can serve as a power source for homes, businesses and even communities. 

A Battery Energy Storage System (BESS) is technology designed to store energy for later use. Battery energy storage systems have a wide range of applications. Commercial applications include peak shaving, load shifting, emergency backup, and various power grid services. Residential applications include self-consumption, off-grid homes and emergency backup. 

Empowering a sustainable future with TERREPOWER

TERREPOWER, a division of BBB, is the only company of its kind that sustainably manufactures EV and hybrid batteries, solar panels and battery energy storage systems. 

According to Pew Research, most homeowners who have considered installing solar panels want to save money and help the environment. They look for sustainability and environmental benefits. TERREPOWER combines these benefits with EV batteries for energy storage.

"The exciting part is our sustainability value. TERREPOWER is applying its over 35 years of remanufacturing expertise to EV batteries, energy storage systems and renewable energy systems. The work we are doing today will positively impact future generations," said Maria Caballero, president of TERREPOWER.

Looking ahead, the EV battery life cycle will be a growing industry. Innovations in material sourcing, manufacturing efficiency, battery storage and recycling technologies are poised to revolutionize the industry, with TERREPOWER leading the way.

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