Second-Life Assessment of Commercial LiFePO4 Batteries Retired from EVs

LiFePO4 (LFP) batteries are well known for their long cycle life. However, there are many reports of significant capacity degradation in LFP battery packs after only three to five years of operation. This study assesses the second-life potential of commercial LFP batteries retired from electric vehicles (EVs) by evaluating their aging characteristics at the cell and module levels. Four LFP cells and four modules were subjected to aging tests under various conditions. The results indicate that LFP cells exhibit long life cycles with gradual capacity degradation and a minimal internal resistance increase. Module-level analysis reveals significant balance issues impacting capacity recovery. Incremental capacity analysis (ICA) and post-mortem analysis identify the loss of active materials and lithium inventory as key aging mechanisms. This study provides the optimal working conditions of second-life LFP batteries and suggests that, with proper balancing systems, LFP batteries can achieve extended second-life use in stationary energy storage applications, emphasizing the importance of effective balance management for sustainable battery utilization.