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Electric mobility is undoubtedly becoming the new norm, with electric vehicle (EV) sales breaking records every year. However, EVs are not without criticism—there has been much debate about the true sustainability of electric vehicles, and their batteries are typically the main culprits.

A bare EV showing the base where the EV battery is located.

The concern is understandable: we are all too familiar with the batteries in our phones and laptops, which lose much of their capacity in just a few years—or worse, fail outright prematurely.

Unlike the batteries in our devices, EV batteries are designed from the ground up for long-lasting, high-intensity performance. As a result, they generally last much longer, averaging 15 to 20 years.

But even the most durable battery will eventually reach the end of its useful life. So, what can be done with used EV batteries? We’ll explain below the recycling processes, as well as how EV batteries can be repurposed or reused.

Let’s explore what happens to batteries once you’re done using them.

How Long Does an EV Battery Last?
Before even thinking about recycling, one of the main concerns people have about electric cars is the lifespan of their batteries. Our research found that 30% of potential EV drivers worry that their car’s battery will die before they’re done using it.

This fear, however, is largely unfounded. Currently, a new battery should last between 100,000 and 200,000 miles (160,000 to 320,000 km) or about 15 to 20 years of driving. Beyond hypothetical expectations, EVs produced a few years ago have shown that their batteries can last well beyond the average lifespan of a car.

An electric car driving fast on the freeway.

Tesla, for example, reports that their batteries are typically used for about 150,000 miles (240,000 km) in Europe without issues. Even if a battery fails prematurely, manufacturers generally include an 8- to 10-year warranty, so it will be covered for most of its lifespan.

Like other electronics, EV batteries will eventually lose some of their maximum capacity with use. That said, the loss is minimal, only about 2.3% per year, and there are ways to extend your car’s battery life, such as not charging every night or only charging to 80%.

What Are EV Batteries Made Of?
While EV batteries will last for years, they will eventually reach the end of their life. To understand how an EV battery can be recycled, we first need to look at what it’s made of.

Like other electronics, EV batteries primarily rely on rechargeable lithium-ion cells to store energy. Beyond lithium, commonly used materials include cobalt, manganese, nickel, and graphite, as well as steel and aluminum for the casing.

Machines assembling and attaching the EV battery to the base of the electric car.

To be recycled properly, these materials must be separated and purified to a point where they can be reused.

Beyond the Car: The Future of End-of-Life EV Batteries
As with most products, an EV battery is all the more sustainable if it can be used for a long time. While recycling recovers raw materials, it remains an energy-intensive process and should be the last resort when a battery can no longer be used in another way.

Fortunately, there are ways to repurpose and reuse old EV batteries, with even more potential for future applications. Nissan, for example, has found that its old EV batteries retain about 60 to 70% of their original capacity after the car is scrapped. While this may not be enough to power an EV, it’s perfectly suited for many less energy-intensive uses.

One of the most popular applications for old EV batteries is electricity storage, whether at the grid level or for individuals and businesses. For example, a project by Eaton, BAM, and our partner, The Mobility House, uses 148 old Nissan Leaf batteries to create a 3-megawatt battery storage system that can smooth out demand peaks at Amsterdam’s Johan Cruijff Arena.

A picture of Amsterdam’s Johan Cruijff Arena.

As renewable energy storage becomes a major challenge for grids worldwide, storage systems made from used batteries could be a promising application that gives a second life to used batteries.

Electric Car Batteries: A Look at Their Recyclability
While reusing old batteries is generally the best solution, sometimes batteries are defective or no longer function well enough to be repurposed. In these cases, recycling is the best option.

Two engineers looking at a dual screen and examining the blueprint file of an EV and its battery.

Recycling lithium-ion batteries is increasingly becoming a priority for countries and companies aiming to reduce their reliance on raw material extraction. Since many materials in EV batteries are rare or difficult to source, recycling ensures these valuable materials are not lost to landfills and are reinjected into the supply chain. Let’s take a closer look at how EV battery recycling works.

How Does EV Battery Recycling Work?
To separate the various components of an EV battery, it is first shredded, and the resulting materials are filtered based on their size and composition. This separates plastics, ferrous (metal) materials, and non-ferrous materials.

An illustration of an EV battery with the recycle logo wrapping around it.

The next step is to extract valuable materials, such as lithium, cobalt, nickel, and manganese. This can be done either by applying high heat to the materials in a process called pyrometallurgy, which burns off non-metallic parts, or by exposing the mixture to chemical solutions that recover the appropriate materials, using a technique called hydrometallurgy.

A futuristic battery glowing blue and wrapped around in data and codes.

While recycling techniques vary, this process can recover up to 95% of a battery’s key raw materials and reinject them into the battery manufacturing supply chain.

Is EV Battery Recycling Safe?
Fortunately, there are increasingly strict regulations regarding EV battery recycling worldwide. The EU already requires that EV batteries be at least 50% recyclable by weight, which will increase to 65% by 2025.

A line of political leaders sitting at a table and discussing policies.

What Are the Benefits of Recycling Electric Car Batteries?
As we’ve seen, EV batteries are made up of many rare and hard-to-source materials, often concentrated in regions with poor human rights and environmental standards. Recycling can help reduce the need for new raw materials, moving away from unethical and problematic supply chains.

A stack of Li-ion batteries placed on the floor with a printed recycle sign.

Recycling also helps preserve the environment. On one hand, recycling a battery, while still energy-intensive, consumes far less energy than creating one from scratch. Secondly, recycling a battery prevents it from ending up in a landfill, where its components could leach into groundwater and pollute drinking water supplies.

Electric Car Batteries and the Circular Economy
As the number of electric vehicles on the road continues to grow exponentially, it’s critical to consider the end-of-life of their batteries to ensure electric cars are as sustainable as they claim to be.

Recycling can help recover a significant portion of the materials used and reintroduce them into the battery supply chain, creating a true circular economy. Beyond recycling, there are several ways to repurpose and reuse old EV batteries, thereby extending their useful life.

If you’re wondering how sustainable electric cars really are, from their manufacturing to their use and end-of-life, check out our dedicated article on the topic.