EV batteries get new life helping to build new cars

Nissan Australia has announced it is launching a circular economy project in Victoria, with the Nissan Casting Australia Plant (NCAP) to use recycled batteries from the company’s Nissan LEAF vehicle to power part of its production facility.

The NCAP Battery Project, called Nissan Node, will see a new solar array installed at Nissan Casting Australia, as well as new EV chargers.

In its most simplified form, the Nissan Node will include the installation of a new battery energy storage system made of nine repurposed Gen 1 Nissan LEAF batteries, which will be charged via the solar array.

As a true circular economy project, it uses end-of-life batteries from the Nissan LEAF and renewable energy to power part of the production of components for Nissan’s global EV models, as well as to help supply the new EV chargers to recharge staff vehicles.

The project is estimated to reduce Nissan Casting Australia’s annual CO₂ emissions by 259 tons, while saving 128 MW of energy every year.

“This isn’t just a hugely exciting project, but an important step into the future for end-of-life EV batteries,” said Nissan Casting Australia Managing Director Peter Jones. “As an early pioneer of the electric vehicle both globally and locally, we can also demonstrate leadership in second-life battery initiatives. I’m proud that this solution is every bit as innovative as the launch of the LEAF in Australia was more than 10 years ago.

“Already the Nissan LEAF comes with vehicle-to-grid technology from factory, which will allow Australian EV owners to use their vehicle to power their homes, and could be used to help stabilise the electricity grid, but commercial circular economy projects like this are a viable, sustainable and innovative solution for end-of-life EV batteries, too.”

Nissan’s NCAP operation was established in 1982, and today, in excess of 50% of NCAP’s operation is dedicated to the manufacturing of high-quality aluminium castings that are fitted to Nissan’s battery electric and hybrid vehicles sold globally. Every Nissan LEAF EV sold globally has components fitted that were manufactured here in Australia.

Similar projects are already underway around the world, including a trial with the East Japan Railway Company that uses second-life LEAF batteries to power railway crossings, and with the 4R Energy Corp in Japan, which is developing the technology and infrastructure to recycle, resell and reuse the batteries in Nissan EVs as a power storage solution.

Nissan Node project. For a larger image, click here.

The Node Project is being completed in partnership with Melbourne-based company Relectrify, a developer of battery management and inverter technology that extends the life of batteries, reduces battery system costs and enables the repurposing of high-quality second-life batteries from electric vehicles.

Relectrify’s ReVolve Battery Energy Storage System being installed at the NCAP is a first-of-its kind product built from end-of-life LEAF batteries.

“We are delighted to be working with Nissan on this initiative, which positions Australian innovation at the forefront of the global transition towards both carbon neutrality and the circular economy,” said Relectrify CEO Val Muenzel.

Top image credit: iStock.com/Khanchit Khirisutchalual