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EV Battery Second-Life versus Recycling, An LCA for German OEMs

End-of-life battery management in the automotive industry involves a direct trade-off between cascaded stationary reuse and closed-loop material recovery. Methodological harmonization in life cycle assessment reveals that the ecological viability of second-life systems depends heavily on grid electricity decarbonization and re-manufacturing burdens. Integrating comprehensive inventory modeling enables German original equipment manufacturers to strategically balance regulatory material quotas with absolute greenhouse gas reductions.

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Bachelor's Thesis

Degree:
EV Battery Second-Life versus Recycling, An LCA for German OEMs

Author:

Group

First M. Last

Advisor:

Dr. First Last

City, 2026

Contents

1.2 Problem Statement and Research Questions
1.3 Research Objectives and Scope
2. Theoretical Framework of Traction Battery Circularity
2.1 Degradation Mechanisms and Battery Aging Pathways
2.2 Principles of Second-Life Stationary Energy Storage Systems
2.3 Industrial Hydrometallurgical and Pyrometallurgical Recycling Schemes
Methodology
3.1 Goal and Scope Definition for OEM End-of-Life Strategies
3.2 System Boundary Allocation and Functional Unit Selection
3.3 Life Cycle Inventory and Electricity Mix Sensitivity
Analysis
4.1 Global Warming Potential and Resource Depletion Trade-Offs
4.2 Impact of Grid Decarbonization and Re-Manufacturing Burdens
5. Strategic Implications for German Automotive Manufacturers
5.1 Regulatory Compliance with European Recycled Content Standards
Introduction
1.1 Background and Context of Automotive Electrification
Conclusion
Bibliography

Introduction

Decarbonization strategies across the European automotive industry rely heavily on the widespread adoption of lithium-ion traction batteries, driving substantial increases in upstream critical material extraction and subsequent end-of-life battery volumes [1][2]. For German original equipment manufacturers (OEMs), managing decommissioned battery packs presents a dual challenge: meeting stringent European Union circularity directives while minimizing product carbon footprints across total vehicle life cycles [4][6]. Determining whether immediate hydrometallurgical recycling or secondary stationary deployment offers superior environmental benefits remains a complex multi-criteria optimization problem [2][5].

Methodological divergence in life cycle assessment (LCA) practices complicates this decision-making process, as variations in functional unit definitions, system boundaries, and background grid carbon intensities create substantial fluctuations in reported global warming potential [3][4]. While cascading batteries into stationary energy storage can offset fossil-based peak electricity, the processes of disassembly, diagnostics, and eventual secondary degradation postpone closed-loop material recovery for new battery cells [5][6]. Consequently, OEMs face strategic uncertainty when allocating retired traction batteries between cascade reuse and direct recycling under fluctuating energy mix scenarios [1][4].

This thesis evaluates the comparative environmental performance of second-life stationary integration versus immediate closed-loop recycling for automotive lithium-ion batteries within the German manufacturing and operating context. Employing an attributional and sensitivity-driven LCA framework aligned with international standards, the investigation establishes comparative environmental profiles across multiple midpoint indicators [3][4]. The resulting synthesis provides German automotive manufacturers with an evidence-based decision matrix for sustainable battery lifecycle management and regulatory compliance [2][6].

4.1 Global Warming Potential and Resource Depletion Trade-Offs

Applying life cycle assessment frameworks to automotive traction batteries at end-of-life reveals critical trade-offs between cascaded stationary deployment and direct closed-loop material recovery. When evaluating traction batteries retired from mobile use, cascaded stationary systems temporarily defer recycling processes and mitigate primary battery manufacturing impacts (Bobba et al., 2018). This prolonged operating phase effectively amortizes the initial manufacturing burdens across an extended functional lifespan, thereby lowering overall global warming potential per unit of delivered energy (Kotak et al., 2022). However, as highlighted in ecological impact analyses of industrial battery treatment pathways, direct hydrometallurgical and pyrometallurgical routes yield immediate mineral recovery that reduces virgin resource depletion for critical raw materials such as nickel, cobalt, and lithium (Dewulf et al., 2016). For German original equipment manufacturers, the decision to prioritize second-life deployment over prompt recycling introduces a temporal lag in closed-loop supply chains. Consequently, while stationary storage configurations provide substantial greenhouse gas displacement when offsetting fossil-heavy grid operations, the environmental benefits diminish if battery degradation results in degraded round-trip efficiency during the second life (Bobba et al., 2018; Kotak et al., 2022). Sustainable original equipment manufacturer circularity strategies must therefore balance deferred material recovery against the net life-cycle emissions achieved throughout the secondary service duration.

References

  1. Life cycle sustainability assessment of European electric vehicle battery recycling
    Enrique Moliner, Edgar Contreras, Marja Rinne et al.
    DOI-Link
  2. Second life application of automotive Li-ion batteries: Ageing during first and second use and life cycle assessment
    A. Pfrang, A. Podias, S. Bobba et al.
    DOI-Link
  3. Sensitivity Analysis in the Life-Cycle Assessment of Electric vs. Combustion Engine Cars under Approximate Real-World Conditions
    Eckard Helmers, Johannes Dietz, Martin Weiss
    DOI-Link
  4. Review of current practices of life cycle assessment in electric mobility: A first step towards method harmonization
    Hazem Eltohamy, Lauran van Oers, Julia Lindholm et al.
  5. End of Electric Vehicle Batteries: Reuse vs. Recycle
    Yash Kotak, Carlos Marchante Fernández, Lluc Canals Casals et al.
  6. United States recycled content standards for lithium-ion batteries
    Dunn, Jessica, Kendall, Alissa, Margarett, Slattery
  7. Recycling of Battery Technologies – Ecological Impact Analysis Using Life Cycle Assessment (LCA)
    Lea Unterreiner, Verena Jülch, Sören Reith

Bibliographie

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Diplomarbeit

DIN ISO 690:2013-10 (Ersatz für DIN 1505-2)

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Diplomarbeit

DIN ISO 690:2013-10 (Ersatz für DIN 1505-2)