Lifecycle management framework for used electric vehicle batteries

The growing accumulation of end-of-life (EOL) electric vehicle (EV) batteries poses significant environmental challenges, despite EVs contributing to the global Sustainable Development Goals (SDGs). Improper recycling and disposal can cause eutrophication from lithium battery leaching and release harmful pollutants, such as toxic dioxins from lead-acid pyrolysis. This study develops a much-needed comprehensive lifecycle management framework designed to extend EV battery usability and reduce premature recycling impacts. The framework is guided by four key performance indicators (KPIs): state of health (SOH), state of safety (SOS), remaining nominal capacity, and battery chemistry. These KPIs support optimal allocation of retired batteries to second-life applications, including battery energy storage systems (BESS) for variable renewable energy systems (VRES), refurbishment, or recycling. The framework introduces a QR code-based battery passport system that enables real-time diagnostics and supports informed decision-making while ensuring compliance with government recycling regulations. To evaluate performance, MATLAB simulations were conducted and compared with standard machine learning models trained on the same KPIs. Results demonstrate that the proposed framework achieves higher classification effectiveness (98%) and superior environmental effectiveness than most benchmarked models (91.04%), while also incurring the fewest classification errors (1) compared to contemporary models. The findings highlight the potential of structured lifecycle management to mitigate environmental risks, optimize material recovery, and support the sustainable growth of EV adoption.