Edited by: Tecnológico Superior Corporativo

Edwards Deming

January - March Vol. 7 - 1 - 2024

https://revista-edwardsdeming.com/index.php/es

e-ISSN: 2576-0971

Received: june 29, 2023

Approved: October 20, 2023

Page 1-13

Electric vehicle battery reconditioning analysis

Análisis de reacondicionamiento de baterías de vehículos

eléctricos

Juan Carlos Rubio Terán

Sebastián Nicolás López Nasimba

Natalia Milena Pérez Zambrano

ABSTRACT

The life cycle of an electric vehicle battery comes to an end

when it no longer provides the necessary capacity to

perform optimally in the vehicle; however, there is a new

possibility of reusing it in another field of study. An analysis

of the state of the battery is of utmost importance since

this is the starting point to define the feasibility of the first

stage of this study. In Ecuador there are some areas that

do not have electricity service, that is why this research

generates a contribution to society with an emerging

system that has the ability to light an LED lamp through the

energy of the battery that was assumed would no longer

be useful in any field. For this study, the data of the battery

and the consumption of LED lamp were taken through the

experimental method, with measuring tools such as

amperimetric clamp and automotive multimeter. It was

observed that the data obtained from the average

consumption of the lamp is 0.35A, the current state of

charge of the battery after being used in the vehicle has

180V in total of all its cell block and when the lamp is

connected its charge is reduced by 1.4 for every hour that

the lamp is kept on. It was evidenced that based on the

data obtained, the battery does have the capacity to light

the LED lamp and meets the objective of this study to be

able to reuse it in another area other than automotive.

* Ingeniero Mecánico Automotriz, MBA Mención Medianas

y pequeñas industrias, Universidad Internacional del

Ecuador, UIDE, jrubio@uide.edu.ec

https://orcid.org/0000-0002-5815-0154

* Estudiante Carrera de Ingeniería automotriz, Universidad

Internacional del Ecuador, UIDE, selopezna@uide.edu.ec

https://orcid.org/0009-0009-6069-6736

* Estudiante Carrera de Ingeniería automotriz, Universidad

Internacional del Ecuador, UIDE, naperezza@uide.edu.ec

https://orcid.org/0009-0004-5112-8570

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Keywords: batteries, batteries, vehicles, electric,

pollution, lithium, reuse, capacity, awareness, disposal.

RESUMEN

El ciclo de vida de una batería de un vehículo eléctrico llega

a su fin cuando no presta la capacidad necesaria para

cumplir un desempeño óptimo dentro del vehículo, sin

embargo, existe una nueva posibilidad de reutilizarla en

otro campo de estudio. Realizar un análisis del estado en

el que se encuentra la batería es de suma importancia ya

que desde ahí se parte para definir la viabilidad de la

primera etapa de este estudio. En Ecuador existen algunas

zonas que no cuentan con un servicio eléctrico, es por ello

que en esta investigación se genera un aporte a la sociedad

con un sistema emergente que tiene la capacidad de

encender una lámpara de luz LED a través de la energía de

la batería que se asumía ya no sería útil en ningún ámbito.

Para este estudio se tomó los datos de la batería y el

consumo de lámpara LED a través del método

experimental, con herramientas de medición como pinza

amperimétrica y multímetro automotriz. Se observó que

los datos obtenidos de consumo promedio de la lámpara

es de 0.35A, el estado de carga actual de la batería después

de ser utilizada en el vehículo cuenta con 180V en total de

todo su bloque de celdas y al ser conectada la lámpara su

carga se reduce en 1,4 por cada hora que se mantenga

encendida la lámpara. Se evidenció que en base a los datos

obtenidos, la batería si cuenta con la capacidad para

encender la lámpara de luz LED y cumple con el objetivo

de este estudio de poder reutilizarla en otro ámbito que

no sea automotriz.

Palabras clave: baterías, vehículos, eléctricos,

contaminación, litio, reutilización, capacidad, conciencia,

desecho.

INTRODUCTION

The handling and disposal of electric vehicle batteries in Ecuador is a problem that

generates many doubts, especially what is done to reduce and mitigate the pollution

that these batteries generate to the environment when they reach the end of their

useful life. According to (Börner et.al., 2022) the life cycle of a battery starts with its

production, development and assembly in the vehicle. After the battery has fulfilled its

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e-ISSN: 2576-0971

useful life and has been removed from the vehicle in an orderly process, its new stage,

also known as its second life, begins. To classify a battery, we start from an evaluation

of each and every one of its components, continuing with the battery cells, its electricity

and its outer body or casing. Among the factors that enter into analysis are taken into

account from its manufacture to its last day of use, where possible problems related to

the quality of its production and the way it was used, particularly its maximum power,

real temperature conditions and the memory in its charging habits are denoted.

Within this research we analyze a battery of an electric vehicle where we study the

capacity and state to which it is after being used in its maximum performance within the

vehicle, i.e., study the benefits so that based on this define the feasibility of carrying out

a project to create a pop-up light generator for a home, where in one way or another

the study maintains an approach to generate a culture of awareness in society that

allows using parts or elements that were believed to have fulfilled their useful life. (Maisel

et.al., 2023) mention that in the recycling ideology a good way to handle batteries that

have reached their useful life is to recycle their metals such as cobalt or lithium that

they contain to create new batteries where their manufacturers use this process and

thus generate a sustainable economy and considering not to overexploit the source of

metals that are known to be not unlimited. The use of clean energy is a potential

solution to reduce the environmental impact as mentioned by (Picatoste et.al., 2022).

The automotive industry states that in Ecuador the vehicle market has been in constant

movement and the entry of electric vehicles to the market attracted the attention of

many users who bet on this technology being mostly people looking to save, but for

some time the batteries of these vehicles have not been given a correct management in

the disposal process that in reality there is no information about what happens to these

batteries, which is why it is planned to give ideas of projects that seek to use them in

another field outside the automotive industry. An important aspect is referred to by

(Al-Wreikat et.al., 2022) when mentioning that electric vehicle batteries can continue

to operate in an energy storage mode for about ten years where the waste produced

by the batteries as such is significantly reduced, thus maximizing their useful life and put

in fields where their application is in lower power intensity and avoid being discarded.

The reuse of electric vehicle batteries as energy storage systems generates

environmental and even economic benefits depending on many factors according to the

area in which they are intended to be used, whether commercial, residential or even

industrial. These factors can influence the economic approach to the reuse of electric

vehicle batteries such as their cost at the time of purchase, the addition of solar energy

supplements and their remaining capacity status.

The purpose of this research is to carry out the first part of a feasibility study of an

emergent light generator so that there is an analysis and studies where future

generations will continue with this study, which can be rechargeable with solar panels,

taking into account the properties of a battery of an electric vehicle, considering that

the reuse of this is possible and where it is given a second useful life that generates

energy for its users. Through the analysis of the battery of an electric vehicle, we seek

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e-ISSN: 2576-0971

to define the consumption and charging capacity of the battery to generate energy in a

given range of time. Knowing the limits and benefits that include the reconditioning of

the batteries is another challenge within this research, it is a fundamental parameter for

the development or not of the project since it depends on this to start with its

implementation and subsequent construction with its respective elements, as well as

something that is totally attached to reality.

Implement in different homes an alternative solution to the sudden loss of energy and

keep it for a range of time, thus taking advantage of its storage capacity where it seeks

to give another approach that does not involve the automotive industry. After fulfilling

its life cycle in the electric vehicle can still take advantage of its capacity in terms of

energy issues and that in turn with this principle includes the application of the circular

economy is another of the objectives that are raised in this research where the

resources already available are maximized and not incur the need to extract more

materials for processing and production thus reducing the environmental impact

involved in this whole process.

Generate awareness in the responsible management of battery disposal in both users

of electric vehicles and society in general to mitigate the pollution that these and their

compounds produce, being lithium one of the main pollutants of batteries that is also

considered highly toxic and that along with this element there are problems of mining

in many cases excessive that have left in their way fragile ecosystems and no doubt that

future generations use this study as a basis for if possible to apply it in a large-scale

project where more families in Ecuadorian territory will benefit. Batteries are called as

an energy accumulator used by vehicles for starting, ignition and some other electrical

and electronic systems, the time that most fulfills its performance a battery is at the

time of cold start. It has the competence to store and deliver the electrical energy

produced by means of an electrochemical process, the same one that converts chemical

energy into electrical energy. It is responsible for maintaining high current for a certain

time while the vehicle is turned off and thus start its engine. (Guevara, 2017).

Electric vehicle batteries

An electric vehicle battery stores electrical energy, which is obtained through reversible

oxidation and reduction chemical reactions, composed of two electrodes, one positive

and one negative, together with a separator. The stored energy comes mostly from the

electrical grid, from a heat engine or from the energy generated during vehicle

braking.(Díez, 2019).

The charging and discharging process of batteries occurs through a chemical reaction,

in which electrons flow from one electrode to another through an external circuit by

means of terminals. The performance of a battery depends largely on the characteristics

of the cells or elements used to manufacture it. A cell is the combination of several

electrode-electrolyte assemblies. (Díez, 2019) The amount of energy of the electric or

high voltage battery is gradually reduced when the vehicle is not driven, in the same way

this battery can be reduced if the vehicle is parked for a long time in places that present

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e-ISSN: 2576-0971

a high or low temperature. The distance of travel may vary depending on the driving

conditions of the user, although the amount of charge is the same. The electric battery

may consume more energy when accelerating repeatedly or driving uphill, as it

consumes more energy. In the same way, this battery is consumed in a shorter time

when using the air conditioning or heating which will trigger with the reduction of its

travel distance.(Peralta, 2018).

The electromobility market has grown steadily in recent years. To ensure a future

supply of raw materials for the production of new batteries for electric vehicles, it is

essential to estimate the future demand for battery metals. According to the growth

and technology scenario, future demand for lithium and cobalt exceeds current

production by up to 8 times by 2040. Nickel exceeds current production in one

scenario. For manganese, future demand in 2040 remains well below current

production. The recycling potential for lithium and nickel is more than half of the raw

material demand for lithium-ion batteries in 2040 (Maisel et.al., 2023). Huge landfills of

used lithium-ion batteries (LIBs) have emerged worldwide as a consequence of their

extensive use in electric vehicles. With the increasing scarcity of LIB raw materials,

recycling of spent LIBs has become a key part of a sustainable approach to energy

storage applications, taking into account the potential economic and environmental

benefits (Wei et.al., 2023). Since reuse introduces the use of additional materials and

processes, its environmental impacts need to be systematically studied, understood in

a life cycle perspective and improved. Several studies in the literature have reported life

cycle impacts of reuse processes, this involves separating both anode and cathode active

materials with high purity from spent LIBs and then regenerating their electrochemical

performance through various mechanical, chemical and physical processes.(Shen et.al.,

2023).

Battery types

• Lead-acid: they are commonly used in the automotive industry due to their high

reliability and low cost. These batteries have reached a good technological

development and have predominated in the automotive market. However, they have

some disadvantages such as low energy density, high weight or the need for

maintenance that makes them worse in terms of performance than lithium-ion

batteries.(Perez, 2021).

• Nickel-cadmium: their main advantage is their high durability. They can be completely

discharged without damage and can be recycled. However, their use in the

transportation sector is not cost-effective (Pérez, 2021).

• Nickel-MH: these batteries are commonly used in hybrid vehicles and pure electric

vehicles due to their many advantages such as their energy density, although not as

high as that of lithium-ion batteries, has an acceptable value; the number of charge

and discharge cycles it can withstand is high, provided that the discharge rate of the

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e-ISSN: 2576-0971

battery is not very high; it can operate in a fairly wide temperature range and is

harmless to the environment, besides being recyclable. (Pérez, 2021).

• Lithium-ion: these batteries have become a favorite for electric vehicle

manufacturers because, despite their high price, they have a specific energy and

power density and a higher cell voltage than other batteries. They also have a longer

life cycle, can be recycled and do not require much maintenance. This type of

batteries responds to the fundamental characteristics required by current batteries

such as their weight which is very light, the discharge is slow and the recharge time

is relatively fast, being one of the best that are currently technologically viable. (Pérez,

2021) Li-ion batteries are the third most marketed type for EV applications. Since

Lithium is the metal with the highest negative potential and the lowest atomic weight,

batteries using Lithium have the greatest potential to achieve the technological

breakthrough that will provide EVs with the greatest performance characteristics in

terms of acceleration and range.(Triana, 2017)

MATERIALS AND METHODS

Electric vehicle battery: A KIA SOUL electric vehicle battery given to the university as a

donation from the private company was used as an emergency energy storage source.

This battery provides energy storage.

Figure 1. Kia Soul battery

Source: Authors, 2023

LED lamp: A 72W LED lamp was used for testing. This lamp provides sufficient

illumination for one room.

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Figure 2: LED lamp

Source: Authors, 2023

Clamp ammeter: The clamp was used to collect data on lamp consumption over a period

of one hour and the current battery voltage.

Figure 3: AC/DC Current clamp meter

Source: Authors, 2023

Automotive multimeter: The multimeter was used to measure the battery charge.

Figure 4: Trisco DA-830 Automotive Multimeter

Source: (Electrónica, n.d.)

The research methodology used in this study was based on literature review, data

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collection and analysis through the experimental method.

Literature review: An exhaustive research and review of scientific articles on electric

vehicle batteries was carried out to obtain information on the specifications, properties,

limitations and external applications of electric vehicle batteries, as well as the energy

storage capacity, which depends on the characteristics of the battery tested.

Data analysis: The data collected from the literature review were analyzed to identify

the main variables affecting the performance and storage capacity of discarded electric

vehicle batteries.

Parameter selection: Once the data analysis was completed, the key parameters to be

considered for the construction of the system were identified.

Electric vehicle battery selection and conditioning: To start with the implementation of

the emergency system, the first step was the selection of the electric vehicle battery

(KIA SOUL). The battery was selected based on its residual capacity and general

condition.

RESULTS

Preliminary tests were carried out to evaluate the capacity of the battery intended to be

used in the research, from which the following results were obtained: lithium block cells

placed in parallel with a charging capacity of 180v.

For the connection of the LED lamp, its terminals were connected to the battery poles,

making a proper and safe connection. The operation of the lamp was checked and the

necessary adjustments were made to ensure efficient lighting in the place where the tests

were carried out (UIDE motor laboratory).

Figure 5: LED lamp operation

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Source: Authors, 2023

Performance Tests: Finally, system performance tests were conducted, verifying the

lamp's power consumption over a one-hour period. The battery capacity was evaluated

before and after the test to provide reliable backup power during emergency situations.

Data

Table 1: Consumption data based on time collected from the battery and its decreasing

charge.

Time (min)

Consumption (A)

Battery charge (V)

0.34

180

0.35

179.8

0.35

179.5

0.35

179.3

0.36

178

0.35

178.8

0.36

178.6

Source: Authors, 2023

Figure 6 calculates that the average power consumption of the LED lamp is 0.35 Amps

and the voltage difference from the time the lamp is turned on until it is turned off is 1.4

Volts, after the lapse of 1 hour.

Figure 6: Calculation of average consumption, battery charge difference and standard

deviation.

Source: Authors, 2023

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For this study it is proposed to use three LED lamps that generate 8 hours of energy

and illuminate the place where it is required. The average consumption of the lamps is

1.05 Amperes and the battery charge level will be reduced by 33.6 Volts, still maintaining

charge inside its cells, which means that it is possible to provide energy for more than

the 8 hours studied under the established parameters.

Figure 7 shows that the consumption of the LED lamps during the 8 hours is maintained

and their load reduces.

Figure 7 : Graph of load and consumption over an eight-hour range.

Source: Authors, 2023

It is important to take into account that this is the first part of the project, since later

another study must be carried out to analyze and implement the charging of this battery

with solar panels that provide considerable autonomy to the system.

DISCUSSION

This study established an alternative for reusing the battery of the electric vehicle, while

reducing the environmental impact, it has been shown that by identifying the

performance and characteristics of this battery it is possible to develop this project.

Thus, analyzing the feasibility of generating electricity in places where this service is not

available, combined with the control of electric vehicle battery waste, presents a key

opportunity to promote energy sustainability and improve the quality of life of users.

The behavior of the battery is optimal for reuse, it is important to mention that this

research can be applied in macro fields, that is, in a much more industrial way, as long

as the batteries and complements are available to carry it out, where it is possible to

charge the battery with solar panels and extend the time of energy that these provide

for the possible use of artifacts. Within the country it has not been considered to give

them a new use to these batteries, only studies have been carried out but not to apply

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e-ISSN: 2576-0971

it in any practical field, and that is where the possibility of creating an emerging system

was found.

In conclusion, ensuring that the study is accessible allows different stakeholders, such as

investors, experts in the field and the general public, to understand and assess the

feasibility of the project in a transparent manner, facilitating informed decision making

and encouraging the active participation of different people and organizations, as well as

supporting the feasibility of the project through the study, providing concrete evidence

of its operation, thus generating support and confidence in the project.

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