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Optimal design of electric vehicle battery recycling network

Lygizos Aristotelis

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Summary

The management of electric vehicle batteries at the end of their life (EoL EVBs) is a matter that will require particular attention in the near future. According to estimates, lithium batteries in electric vehicles have a lifespan of ten to fifteen years. Once they reach the end of their life cycle, these batteries are classified as waste. The implementation of strategies such as recycling, reuse, and remanufacturing should be considered from both an economic and environmental standpoint. In Greece, there is no network for the collection and management of this waste due to insufficient quantities to support such infrastructure. This final year project presents an integrated system for the collection, recycling, and remanufacturing of lithium-ion batteries from electric vehicles in the Region of Attica. Considering the national and European initiatives focused on advancing electromobility and taking into consideration the historical data of electric vehicle sales in Greece, the projected production quantities were estimated. Initially, this approximation was made on a nationwide scale and subsequently refined to the region of Attica. Upon completion of the waste quantity calculations for two different scenarios up until the year 2040, an investigation was conducted to determine the optimal locations for collection network facilities. Such facilities would undoubtedly exert a substantial influence on the comprehensive economic analysis. Based on two waste production scenarios, it is anticipated that the region of Attica will have to manage between 4,300 and 7,300 tonnes of End-of-Life Lithium-ion Batteries (EoL LIBs). Initially, four scenarios for the location of infrastructure were formulated and examined, ultimately leading to the selection of the most economically and environmentally advantageous option. Subsequently, the operational costs, transport and processing costs, as well as the CO2 emission tax imposed by the European Union, were computed to present a comprehensive overview of the network. Finally, calculations were performed to determine the network's revenue, derived from the recovery of valuable metals present in lithium batteries and the sale of reassembled batteries meeting the required specifications. After computing the aforementioned parameters and approximating the investment costs needed for implementing the network, a comprehensive economic analysis was conducted. This analysis entailed the calculation of significant economic factors to assess the investment. The payback period for the network investment falls within the range of 6 to 8 years, which proves highly advantageous since it is considerably shorter than the planning period for such an installation. This research is characterized by its multifaceted nature as it takes into consideration numerous factors and data, ultimately presenting an integrated network for managing electric vehicle batteries in Attica.

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