Audi gives old E-Tron batteries a new lease on life

Audi is trialling an electric vehicle charging hub that will use repurposed lithium-ion batteries from old E-Tron vehicles connected to renewable energy sources.

The trial is part of the German carmaker’s ambitious goal to be a zero-net carbon vehicle manufacturer by 2050.

The German carmaker, which has already committed to carbon-neutral production at all its plants by 2025, has committed to using 100 per cent renewable energy and recycled materials throughout its production process and supply chain.

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However, the energy-intensive production of lithium-ion batteries, which is responsible for almost a quarter of all carbon emissions of producing each of its electric vehicles, creates significant challenges to its sustainability goals.

So it plans to reduce the batteries' carbon footprint by giving them a second life powering the charging hubs in portable 11kW power ‘cubes’ that can hook up to an existing 400-volt three-phase connection, which makes it easier to find a suitable location without the planning time and resources required to build all-new infrastructure.

The pilot charging hub in Nuremberg will use three storage cubes with batteries sourced from disassembled E-Tron development vehicles. It will have a total capacity of 2.45-megawatt hours, enough for 70 quick charges of up to 300kW per day through six charging ports.

They will be charged overnight using just 200kW of off-peak green energy and topped up during the day by solar panels on the roof, meaning there will be no strain on the power grid during peak times.

The charging hub’s project manager, Ralph Hollmig, said a portable lounge area, built from sustainable materials, will also be erected on-site to provide a place for drivers to spend the charging time.

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“Charging an electric Audi model only takes a little longer than a coffee break.

“With our lounge, it will be particularly entertaining or it can be used, for instance, for business appointments,” Hollmig said.

According to Audi, the Cube will be available to all EV users and will cost the same as other chargers around Germany.

If successful, the Audi Charging Hubs will be rolled out to other parts of Germany and possibly to other markets.

Once, and only when, batteries can no longer fulfil their second-life applications, they are broken down into their individual raw materials in order to be used again in new batteries.

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Audi is not the first company to give batteries a second life once they are no longer suitable for vehicle use.

Old Nissan Leaf batteries have been repurposed for home battery storage and other applications such as portable energy for tradies and even boats.

And in Melbourne, power solutions firm Relectrify is rolling out second-life lithium-ion batteries for high-capacity power storage for commercial and industrial applications throughout Australia.

Other ways Audi is working to achieve its net-zero emissions target is to use 100 per cent renewable energy, treated wastewater, and recycled materials throughout its vehicle production cycle and supply chains.