Aussie plan to crack lithium-ion battery riddle

An Australian company is launching a research project into remanufacturing lithium-ion batteries.

Melbourne-based Injectronics revealed its intentions this week, at the same time it announced it was rolling out a Nickel-metal Hydride battery remanufacturing program for the Toyota Camry and Prius.

Injectronics says its NimH battery remanufacturing business is an Australian-first and says remanufacturing of lithium-ion batteries – which are found in most plug-in hybrids and electric vehicles – would be a world first.

“We are in a position where we are going to employ a mad guru and start that research,” said Injectronics executive general manager Gino Ricciuti “We are probably going to partner with some universities to really explore this.

“We don’t even know if it can be done. It’s a moon shot. It’s going in without any expectations of anything.

“Part of it could be we get to a point where we say it can’t be done. No-one in the world has done lithium-ion [remanufacturing]. We may even partner with overseas people.”

Part of IM Group, Injectronics is a supplier of new and remanufactured automotive electronic components, as well as a  repairer of electronic and mechatronic parts.

Its NimH battery remanufacturing and swap scheme allows automotive workshops to order a refurbished pack to be delivered within 24 hours.

Injectronics will swap the old battery pack for new, test the cells at its laboratory, fix the failed ones and then store the cells for installation in a pack destined for future sale.

It hasn’t yet settled on the final price of its remanufactured Prius and Camry battery packs, but estimate they will be 60 to 80 percent of new ones. The packs are guaranteed to come with full as-new performance and are protected by a two year warranty.

The final price will depend on the level of training and safe guards required for the swapping process.

Taxi fleets are expected to be a major initial customer for the remanufactured battery packs with the aim of improving the fuel efficiency of the cars by allowing them to utilise the electric motor for assistance more often.

According to pricing supplied by Toyota Australia, all Prius and Camry replacement batteries cost less than $3000 plus GST.

Currently, only battery pack repair – rather than remanufactured replacement – is offered in Australia as an alternative to a new hybrid battery pack.

Injectronics estimates the number of batteries potentially requiring replacement will climb from about 16,000 in 2021 to around 23,000 annually in 2024. With hybrid sales topping 60,000 in 2020, the potential future market is significant.

As cells age and potential performance dips, Injectronics is considering developing a business to convert them for home battery storage. It is also planning battery export to New Zealand.

Beyond the lower price for customers, the new scheme also has environmental benefits, as it salvages battery cells and their toxic materials that could otherwise be consigned to landfill.

“A project of this type creates a circular economy, putting to an end the single use nature of hybrid batteries, is environmentally friendly in its approach and will save hybrid vehicle owners a considerable sum when their battery fails to work as expected,” Ricciuti said.

A Toyota Australia spokesman said the company was unaware of the Injectronics program.

“Toyota has its own battery recycling and repair initiative which it uses to replace batteries and recycle them in an environmentally conscious and responsible manner,” the spokesman stated.

“In excess of 98 percent of the battery materials are diverted from landfill, and all toxic elements are removed. This program also includes the incentive of a cash rebate when you return or a discount when you return and replace a hybrid HV battery.”