Passenger car and light-duty EV (Electric Vehicle) sales have reached 17.1M in 2024 with 11M in China, 3M in Europe and 1.8M in U.S.A and Canada. Overall, global EV sales grew by 25% in 2024 compared to 2023 [1] . In Türkiye alone, passenger car EV sales in 2024 were up 51,7% compared to 2023 and the market share has risen from 6,8% to 10,1% [2].
Electric vehicles (EVs) are projected to achieve a 75% market share in EU countries by 2030, with one in four vehicles on the European Union (EU) market being electrically powered. The electricity demand for charging passenger and commercial EVs in the EU is expected to rise significantly, from 9 terawatt-hours in 2021 to 165 terawatt-hours by 2030. To support this growth, the EU will require at least 3.4 million operational public charging points by 2030. Developing the EV charging infrastructure, including installing new charging stations, upgrading power grids, and expanding renewable energy generation could cost more than €240 billion by 2030 within the EU alone [3]. As a result, global demand for lithium batteries is rapidly increasing, with annual consumption projected to reach approximately 5.7 terawatt-hours by 2035 [4].
The second life of batteries refers to their extended life after completing the first life in an EV. During their time in an EV, batteries undergo demanding charge and discharge cycles, gradually reducing their capacity. A battery pack is typically considered to have reached the end of its first life when its capacity declines to 70-80% of the original. However, its second life can extend until the battery’s state of health (SoH) drops to 30%. At this juncture, EV manufacturers face three options for the used batteries: recycling, disposing, or reusing them in their second-life. Reutilization of EV batteries in their second-life provides the most economical and environmental option for EV manufacturers. This creates significant opportunities to repurpose these batteries for stationary applications, such as energy storage systems (ESS) or EV charging stations.
Proposed second-life EV charger station solution
In demonstration 7, we propose using different types of LiFePo4 (LFP) second-life batteries as an energy storage solution (ESS) in an EV charger station with solar photovoltaic panels and a utility grid connection. The power distribution unit (PDU) monitors and controls the AC/DC conversion for DC charging of battery modules and AC charging of EVs via the utility grid. The battery cell parameters such as voltage, current and temperature are measured by the battery management unit (BMU). The battery pack state of health (SoH) and state of charge (SoC) parameters are computed by the battery control unit (BCU) and provisioned to the cloud system via the telemetry module.
Demonstrator 7 outlines the utilization of different types of second-life batteries as storage solutions for charging electric vehicles (EVs). Second-life battery modules will be provided by different manufacturers and with corresponding system specifications. The battery management system (BMS) which comprises BCU, BMU and internal communications structure will ensure efficient control of battery modules. The photovoltaic cells will provide renewable energy for DC charging and the power grid will supply the energy for AC charging of battery modules. The EV charger system will be able to charge two EVs in DC or AC simultaneously.
Advanced BMS system with AI/ML algorithm development for SoX/RUL estimation
Advanced AI/ML development on the BCU board for SoX/RUL estimation has been implemented for better accuracy and efficiency.
Contribution to the zero-carbon rating for the environment
Demonstration 7 aims to lower charging costs, increase energy efficiency and provide multi-cell energy management with improved range and lifetime of the battery. Reutilization of second-life batteries in their lifecycle rather than recycling provides cost-effective solution and environmental benefit. This will contribute to the EU’s zero-carbon rating goals by widespread adaptation of the EVs by increasing driver confidence, lower charging and EV costs and efficient charging operations.
It will contribute to the reduction on the peak electric grid load due to EV charging via battery storage systems. Photovoltaic cells also provide a cost-effective way of charging battery modules and as a source of renewable energy. Second-life EV charging solutions provide the means to support grid stability by supplying the energy on high demand by EVs and implementing energy control efficiency. Utilizing second-life batteries for charging helps reduce power utility costs and power loads.
Keynote:
By making use of second-life EV batteries with solar PV panels and utility grid in an EV charger system, we aim to provide substantial benefits to the zero-carbon rating of the environment and widespread EV adoption by reducing EV charging costs, battery life and efficiency.
For more information:
Asaf M. Sofu, WP and Demo Leader (OPEVA)
EU Project Coordinator @ ORTEM Electronics
References:
- URL 1: Rho Motion. (2025, January 14). Over 17 million EVs sold in 2024 – Record Year – Rho Motion. https://rhomotion.com/news/over-17-million-evs-sold-in-2024-record-year/
- URL 2: Anadolu Ajansı (2025). 2024’te 100 bine yakın elektrikli otomobil satıldı. https://www.aa.com.tr/tr/ekonomi/2024te-100-bine-yakin-elektrikli-otomobil-satildi/3444453#
- URL 3: Why the automotive future is electric. (2021, September 7). McKinsey & Company. https://www.mckinsey.com/industries/automotive-and-assembly/our-insights/why-the-automotive-future-is-electric
- URL 4: BloombergNEF (2024). Electrical Vehicle Outlook Report 2024. https://about.bnef.com/electric-vehicle-outlook/, 2024.