A simulation model for assessing the potential of remanufacturing electric vehicle batteries as spare parts

Remanufacturing is a key element of circular economy solutions as it aims at increasing the service lifetime of entire products or specific components, which may reduce the demand for new, resource-consuming devices. To assess the potential of disassembling and subsequent remanufacturing of EV batteries, we present a discrete event simulation approach. This approach depicts the life cycle of batteries and EVs separately, which allows capturing the demand for spare batteries and the potential contribution of remanufacturing batteries to cover this demand. By running various scenarios taking the German EV market as an example, the importance of providing cost-effective spare batteries through remanufacturing is underlined. As a baseline, a linear case is examined, where remanufacturing is not an option. Additionally, we built scenarios where remanufactured batteries are used as spare parts for older vehicles. Another major variation is introduced by different average battery lifetimes (10, 15, and 20 years), while the average vehicle lifetime is 15 years in all cases. The results show that remanufactured spare batteries could decrease the demand for new batteries compared to the linear base case. When battery lifetimes are lower than those of vehicles, new battery demand could be reduced by 6–7%, given our assumptions. In future scenarios where expected battery lifetimes might exceed vehicle lifetimes, up to 2% savings in new batteries could still be possible. Therefore, remanufacturing could be a viable option for improving the sustainability of electric mobility, and (re)manufacturers should consider intensifying their engagement in designing remanufacturable batteries, in research on remanufacturing technologies, and in investing in remanufacturing infrastructure. •Supply of and demand for remanufactured batteries are determined simultaneously.•The model considers incompatibilities between vehicles and remanufactured batteries.•Remanufacturing EV batteries could lower the demand for new batteries.•Frequent changes in battery technology could limit the remanufacturing potential.