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Second life battery safety and performance: changing perceptions

Real-world data has demonstrated that the industry was too cautious in its predictions of EV battery performance. With now a growing body of evidence on second life battery safety, is it time to also shift our mindset and perceptions on this technology?

14/05/2025

Author: Alex Charr, COO

Traditionally, we’ve viewed vehicle components as depreciating assets. And with the evolution to electric, this is even more true, with batteries seen as expensive necessities with limited lifespans. But this perspective is holding back the electrification progress and missing significant financial opportunities.

In brief:

 

  • Just as perceptions about EV battery life and performance are changing for the better, so are perceptions about second life batteries
  • Automotive and battery OEMs were overly cautious about EV battery performance
  • Real world evidence changed these perceptions – and should do the same for second life safety
  • We have been working with second life BESS for over ten years, giving us unparalleled data
  • This enables us to model and predict degradation with incredible accuracy.

Learnings on battery performance

With the launch of the first lithium-powered EVs, we entered unchartered territory, prompting a huge debate about battery life and degradation. Would the batteries last the lifetime of a typical car, or would they degrade too quickly for EVs to be commercially viable?

OEMs carried out significant research ahead of launch – and naturally they were cautious in their forecasts. However, almost 15 years on, we now have huge amounts of data about how the batteries perform. We know that first generation EV batteries are much more resilient than predicted, retaining more of their energy storage capacity for longer than expected.

For example, a recent study by scientists from the prestigious SLAC-Stanford Battery Center at Stanford University found that existing EV batteries may last up to 40% longer than expected. This is because the stop/start journeys on which we mostly use EVs are better for battery health than the steadier use cycles simulated in laboratory tests.

In short, real-world evidence changed our perceptions about battery performance. We believe that the same change in mindset now needs to happen for second-life batteries in relation to their safety.

Changing perceptions on safety

There remains a stigma around second-life batteries that, due to degradation, the batteries present more of a risk.

While it would be unethical to claim that there is no risk from second-life batteries, advances in battery management and rigorous safety protocols are demonstrating the potential for second-life batteries to be deployed safely and effectively.

Firstly, there is now the beginnings of academic research into this topic. A recent study by MEET – Münster Electrochemical Energy Technology at the University of Münster found that battery cell safety increases during ageing, including into second life. Scientists recorded safety improvements all the way from 91% to 63% state of health, where the experiment concluded. Of course, this does not definitively prove that second-life batteries are safe, but it is pointing in that direction.

Secondly, at Connected Energy we have one of the largest and most unique data sets on second-life batteries in the world. We pioneered using second-life batteries in battery energy storage systems (BESS) and have been working with second life since 2010, meaning we have 15 years’ worth of data in this field.

Traditionally, battery and automotive OEMs have focussed their performance analysis on battery capacity from 100% down to 70% at pack level. This is because it is the important operating range for EV performance.  Because we are exclusively using second-life EV batteries, we are typically dealing with battery capacity from 80% downwards. This unique combination of experience and data has enabled us to develop new ways to safely optimise second-life batteries as stationary energy storage assets.

Automotive grade

Another aspect to consider is that EV batteries are the most rigorously tested in the industry. Compared to the batteries in a standard BESS, EV batteries must meet a much higher level of certification and safety. The pass/fail test bar is set significantly higher for an EV battery than a BESS battery. This means that, before a battery goes into a vehicle, it has undergone extensive testing by the OEM to meet automotive grade.

Connected Energy remains distinct in the second life industry because we work in partnership with the OEM to design the BESS around their packs. The OEMs carefully select the packs before they come to us for their second life. We have a close relationship with these OEMs, giving us access to significant levels of battery information. Naturally, this places us at an advantage to those who do not have these deep OEM relationships. This data enables us to ensure we optimise the BESS but also ensure it remains within its operating parameters, for example in terms of min/max temperatures. Our intelligent system also monitors the batteries around the clock, accessing data from the BMS.

If a second-life BESS provider does not have this relationship with the OEM, they would have to reverse engineer the battery, meaning they are unlikely to ever have the full picture. This means in some instances they could be relying on guesswork rather than hard data from the OEM.

Confidence in expertise

How do our OEM partners know that we share their values and high standards around safety?

The answer is simple: We believe in full transparency. We open our doors and welcome them to audit all aspects of our operations. In addition, because we work at a battery pack level rather than cell or module level, we are retaining the OEM’s battery management system (BMS) as well as its thermal management system and other embedded safety systems. This enables us to leverage all the knowledge amassed in that battery pack, including the automotive grade safety systems. We retain all the OEM’s safety mechanisms to prevent thermal runaway such as thermal management, and a high level of redundancy. Furthermore, we are using the packs at a lower C-rate than the original purpose for which they were designed – powering an EV.

Find out more

Connected Energy is a trusted global leader in second-life BESS, working with major OEMs like Volvo and Renault. We welcome discussions with automotive OEMs and battery manufacturers who are interested in partnering with us.

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