Infinitev program to reduce EV battery waste

INNOVATIVE Mechatronics Group (IM Group) has announced an Australian-first battery recycling program for hybrid and electric vehicles that aims to ensure end-of-life batteries are reused, repurposed and recycled as part of a sustainable circular economy.

Dubbed Infinitiev, the program hopes to shift what IM Group calls a ‘take-make-waste’ approach to electrified vehicle (EV) batteries.

IM Group says most EV battery packs ‘fault’ after they lose between 20 and 30 per cent of their capacity because a small number of depleted cells can render the entire pack inoperative.

As part of its Infinitev program, the firm says it can reuse, repurpose and recycle such packs, significantly reducing waste; it estimates that 206GWh of automotive batteries will become waste by the end of the decade – roughly equivalent to the battery packs fitted to three million electric vehicles.

In most cases, battery packs have 70 per cent of their life remaining when removed from vehicles but are discarded at present because they are viewed as a consumable part.

Additionally, less than one per cent of lithium used in batteries the world over is thought to be recycled at present. While Infinitiev admits there are limits to what can be done economically and sustainably, it says steps are already underway to ensure that as much as 70-80 per cent of all lithium used in EV batteries is recycled.

Speaking to media gathered for the launch of the Infinitev program in Melbourne this week, Infinitev general manager Dickson Leow said IM Group’s offering is unique in the Australian market and includes a thorough procedure for handling end-of-life EV batteries.

“Infinitiev is unique in what it offers the automotive industry in the recovery and repair of faulty or end-of-life hybrid and electric batteries,” he said.

Mr Leow went on to describe the program as “the only service provider in the industry that offers a three-pronged program that considers battery reuse, repurpose and recycling opportunities, and the circular economy advantages”.

“Infinitev can enhance an organisation’s environmental and sustainability credentials and eliminate waste,” he added.

Mr Leow said the automotive-specific programs offered by Infinitiev will service OEM and associated dealership networks, as well as independent workshops.

By remanufacturing retired battery packs from hybrid and electric vehicles, repurposing batteries no longer suited to vehicular use into energy storage systems, or by recovering valuable materials for reuse in the creation of new batteries, it is working toward reducing the waste issue created by electric vehicles.

“To help workshops meet the needs of their hybrid battery customers, Infinitev’s hybrid battery remanufacturing exchange project delivers Australia’s first scalable component reuse and resource recovery program for retired battery packs from hybrid electric vehicles,” he explained.

“Until now, a hybrid battery was seen as a single-use part, but Infitiev’s ability to identify and repair battery packs that are faulty, slow to charge, or no longer performing at an effective level provides these batteries with a second life.

“Further, Infinitiev can repurpose batteries no longer suited to vehicle applications as an energy storage system. Developed in partnership with Sustainability Victoria, this plug-and-play industrial grade energy system provides reliable energy peak shaving, load levelling, and potential off-grid power.”

Mr Leow said that in the event battery packs are depleted to an extent where they are no longer holding any charge, they may be recycled to provide materials for new battery construction, reducing the need to source new materials via traditional means.

“The automotive industry traditionally sources materials from the earth to manufacture hybrid and EV batteries, eventually disposing of the faulty product as waste,” he said.

“Infinitiev partners with the automotive industry and other stakeholders to create a sustainable circular economy for EV batteries.

“When batteries reach end of life and can’t be reused or repurposed, Infinitiev partners with industry-leading recycling programs to recover valuable materials that are used to create new batteries.”

Mr Leow said that current data showed hybrid and EV battery packs are beginning to degrade on average from around the six-year mark. Many will fault with 70 per cent of their life remaining, which he said makes them the ideal candidate for the Infinitiev program.

From 10 failed battery packs, the Infinitiev program can return six or seven to the road, the remaining cells then repurposed or recycled.

Those that cannot be returned to service in EVs may be reused in a BESS (Battery Energy Storage System) for industrial use, with the average 120kWh system preventing as much as 42.8 tonnes of CO2 from entering the atmosphere annually (at the source of power generation), or 95.5 tonnes when coupled with a solar array.

Beyond the environmental impact, a 120kWh BESS can save businesses an estimated $18,500 annually on electricity costs – and cover operations in the event of a power outage.

At the moment, Infinitiev can repurpose as many as 50 hybrid or EV battery units per month but new facilities coming online in New South Wales, Western Australia, Queensland and New Zealand will grow that number to 80 units or more, keeping pace with future demand.

The process also covers a wide range of battery types, including NMC, NCA and LFP, as well as future sulphur-based batteries and solid-state arrays.

“We must gear up now before the exponential increase in the number of EVs arrive,” said Mr Leow.

Remanufactured battery packs from Infinitiev are offered with a three-year/40,000km warranty and, according to Mr Leow, can be supplied and fitted for far less than of the price of an OEM-sourced part.

“To use a Toyota Prius as an example, a new battery from the OEM will cost you around $3000 fitted,” said Mr Leow, who went on to outline the two options offered by Infinitev.

“The first would be a comparable aftermarket battery at around $2500 fitted, with a three-year/200,000km warranty,” he explained.

“While the latest option, using the process of the circular economy where we have a workable remanufactured battery, will be around only $2000 fitted, with a three-year/40,000km warranty.”

Mr Leow was also quick to quell safety concerns related to the use of recycled batteries, saying all Infinitiev products are remanufactured to OEM standards.

“We use best practice. So, we have collaborations with our international companies in the US and Europe to ensure that whatever standards they're using, we adopt those same standards, and we're working with the ABR (Australian Battery Recycling) initiative to ensure best practice in recycling as well,” he explained.

IM Group aims to have its Infinitiev program fully operational by March 2024.