Why the EV battery circular economy is key for sustainability

There’s no denying that EV production emissions are higher compared to other fuel types, with reports from Argonne National Laboratory, highlighting a 60% increase for electric vehicles vs. ICE vehicles. This is largely due to battery manufacturing, which is much more complex, requires more mining of raw materials, and has less developed supply chains. 
 
However, this increased energy consumption at production stage is causing a common misconception around EV battery sustainability overall – with many suggesting it’s not what it seems. 
 
The reality? Approximately half of an EV battery’s lifecycle emissions are generated during manufacturing process, and data shows these production emissions are offset within two years of driving an EV. Regions with cleaner electricity grids like Norway and France, show an even shorter offset period – something that is expected to replicate in other regions as grid technology advances. 
 
So, while EV production emissions are higher, it’s important to look at the vehicle’s entire lifecycle emissions to understand their true environmental impact. According to a 2024 report from the International Energy Agency (IEA), EVs have been proven to produce 50% less lifecycle emissions than ICE vehicles over 15 years (or approximately 124,000 miles). It’s also worth noting that EV technology is still being developed, and as new advances come to market, emission savings are predicted to improve further in the near future.

As EV battery technology evolves, so too does our ability to repair and maintain them – a vital step in driving long-term sustainability. Like most technologies, batteries degrade over time and, in rare cases, develop faults. However, that doesn’t mean they need to be discarded right away. 
 
In most instances, the battery issue lies with a single component which can be identified by advanced diagnostic tests and then repaired by expert technicians. 

Remanufacturing takes this one step further, replacing worn materials and rebalancing the battery management system to restore the pack to the original, or better, condition. 

Not only does this delay the need for recycling – an expensive and complex process still in its infancy – but it gives confidence to EV drivers that they can treat their faulty EV in a similar way to an ICE vehicle.
 
Benefits of EV battery repairs and remanufacturing:

• Addresses consumer concerns around EV battery sustainability
• Gives consumer confidence in the servicing capabilities for EVs
• Keeps the battery performing for longer 
• Maximises the use of raw materials already in the ecosystem

Even the most robust EV batteries reach a point where they can’t be repaired, remanufactured or repurposed. At this stage, safe and sustainable recycling is an essential step for sustainability.

For most EV battery variants, the majority of the pack can be recycled, keeping vital raw materials in the ecosystem and reducing the need for mining. But, it’s an energy intensive process that is most suitable after other options have been exhausted. 
 
The journey to net zero doesn’t end with getting EVs on the road. To truly achieve sustainability, we must better manage the resources in the battery.

While the industry works to lower EV production emissions and further decrease an electric vehicle’s lifetime carbon footprint, an EV battery circular economy can be achieved now.
 
At EV Battery Solutions, our advanced infrastructure, engineering excellence and data-led operations are helping our manufacturer and fleet partners to shape a cleaner future. 
 
Talk to our team today to explore how we can support your battery repair and remanufacturing objectives.