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What you should know about EV batteries

Want to know more about EV batteries? Here are some frequently asked questions that will help you increase your knowledge on EV battery safety, longevity and environmental impact.

Environmental

  • ​​ What goes into an electric vehicle battery?

An EV battery is a high-voltage energy storage block that powers your electric vehicle. The battery packs are made of smaller module blocks that contain cells. The cells consist of a cathode (positive terminal), a separator with liquid electrolyte and an anode (negative terminal). 

In terms of the raw materials making up each part of an EV battery, the differences in the cathode side in particular result in the main battery types available here in Australia. These are Lithium-ion, which includes Nickel-manganese-cobalt (NMC) and Nickel-cobalt-aluminium (NCA) and Lithium-ferrous-phosphate, which includes Lithium-iron-phosphate (LFP). You can find all these battery types in EVs in Australia. Each has pros and cons in terms of sustainability, charging speed, storage capacity and longevity. 

  • Are electric vehicle batteries bad for the environment?

Despite EV batteries being energy-intensive to produce, these emissions will be offset during the life of the vehicle. We can’t forget that EVs have zero exhaust emissions, which is good for the environment. This ABC report analysed data from the Electric Vehicle Council that compares the emissions profile of a mid-sized petrol car vs an equivalent EV over 15 years or 189,000km. The data shows that while EVs use more emissions to make before they hit the road, it’s not long before there’s a big switch. Over its lifetime, the EV saves 30 tonnes of Co2 when compared to the petrol car.

When a battery can only recharge to 75% of its original capacity, it can’t be used in an EV anymore. But EV batteries still store significant amounts of energy at this point in their lifecycle, so they can be repurposed. EV batteries are being converted into stationary storage to power homes, buildings and the wider electricity grid. The Electric Vehicle Council says used EV batteries could last up to another 10 years in these functions.

Once the energy capacity has dropped significantly below original levels, these batteries can then be recycled into materials used to build new batteries. This is currently a costly process only available to manufacturers, though it's expected that won't be the case for long. There are hopes of having almost a closed loop where batteries are fully recycled and remanufactured into new batteries. 

And in terms of the sustainability and ethical issues of mining battery minerals such as cobalt, many carmakers are committed to ensuring the minerals they source are traceable and transparent. The same can’t be said for petrol. Manufacturers are also leaning more toward battery chemistries that don’t rely on cobalt, like LFP batteries.

  • ​​​​​​​Can electric vehicle batteries be recycled in Australia?

Yes, old EV batteries are currently recycled in Australia using a combination of onshore and offshore processing. But a lack of batteries that have reached their end of life here is hampering the growth of Australia’s EV recycling industry. The ones that do need recycling are usually due to manufacturer recalls, are out of warranty or are damaged in car accidents. 

Several Australian startups have partnered directly with vehicle manufacturers to provide recycling solutions as demand grows, and there are plans to have the whole process managed in Australia. 

Two people charging an ev

Battery life

  • How long do electric vehicle batteries last?

Most EVs are sold with 8 to 10-year warranties on their batteries and electric motors. But according to the Electric Vehicle Council and other research, EVs are expected to last around 15-20 years, which is considered equivalent to 180,000-200,000 km kilometres driven.

  • What happens when a battery is no longer fit to power an EV?

At their end of life in a vehicle (when charge capacity drops to 75%), EV batteries can be used for potentially up to 10 more years as stationary storage to power homes, buildings and the wider electricity grid. Once the energy capacity has dropped significantly below original levels, it can then be recycled into materials used to build new batteries.

Safety

  • Are EVs more likely to catch fire than petrol or diesel cars?

According to EV Firesafe research funded by the Australian Government, there has been a total of 6 EV battery fires in Australia out of more than 180,000 EVs on the road up to 2023. None of the EVs were charging at the time and the fires were not spontaneous or unexplained. 

Current research suggests EVs are actually less likely to catch fire than petrol or diesel cars. The issue is EV battery fires can be difficult to manage, quickly getting out of control.  

  • What causes EV batteries to catch fire? 

Lithium-ion EV battery fires start because of a process known as thermal runway. This is usually brought on by a battery cell being damaged (by heating, crushing, piercing or overcharge) and short-circuiting. The cell continues to heat up and starts to damage the cells around it because of a chemical reaction in the cells that quickly gets out of control. The energy generated creates more heat, and the process continues until eventually heavy metal dust particles and toxic gas are released. As oxygen mixes with the gas and heat continues to build, the battery cell may ignite, causing surrounding cells to do the same. With most EV batteries under the vehicle, this can set the whole car on fire.  

  • What are the risk factors for EV battery fires?

EV battery fires pose specific risks that are different to internal combustion engine (ICE) petrol or diesel vehicles. These include:

  1. Exposure to a mix of highly flammable toxic gasses from burnt battery cells, metals and plastics
  2. Sudden vapour cloud explosion
  3. Jet-like directional flames
  4. Projectiles from battery cells
  5. Extreme high temperatures up to 1000 degrees Celsius 
  • How do you stop an EV battery fire?

It is crucial to call emergency services immediately if you suspect your EV battery is damaged and has caught fire. Follow their instructions and keep a safe distance from the vehicle.  

Water is the most effective method in suppressing an EV fire, and first responders know the best course of action. EV FireSafe says about 10,000L will be used on average, and it can take several hours to cool the battery down. 

Discover more about AGL's electric vehicle offering, including subscriptions, home charging options and energy plans.

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