• Dagong ESS

How Will Second-Life Batteries Shape the Future of Energy Storage?

What Are Second-Life Batteries in ESS?

As EV adoption accelerates, millions of electric vehicles will retire their battery packs over the next decade. Although no longer suitable for automotive use, many of these packs retain 70–80% of their original capacity—enough for stationary energy storage systems (ESS).

Industry reports indicate that second-life batteries may become one of the fastest-growing segments of the stationary energy storage market.

Types of Second-Life ESS and Compatible Components

Second-life batteries can be integrated into various ESS formats, depending on the health level and module structure of the reused packs.

Common configurations include:

• Rack-mounted second-life battery cabinets (5–30 kWh)

• Industrial-scale second-life modules integrated into 100–241 kWh ESS

• Containerized MWh systems using repurposed battery clusters

When deploying second-life batteries, compatible components are crucial. These include:

• Lithium Battery Stainless Steel Strapping for securing repurposed cells

• Module End Plates to maintain structural stability

• Heat Dissipation Plates for thermal balance

• CCS Cell Connection System for reconfigured battery modules

• Aluminum Busbars for safe current transfer

• Protection Films for insulation and surface reinforcement

These components must be adapted for aged battery characteristics such as higher internal resistance and thermal sensitivity.

Features of Second-Life Battery ESS

Compared with new LFP or NMC ESS, second-life battery systems offer:

• Significantly lower cost

• Reduced carbon footprint

• High availability of EV batteries

• Sufficient performance for stationary uses

• Sustainability advantages

Many integrators pair second-life batteries with air-cooled or liquid-cooled platforms such as:

• 100kWh–144kWh Air-Cooled ESS

• 215kWh / 241kWh Air-Cooled ESS

• 215kWh / 372kWh Liquid-Cooled ESS

• 3.35MWh Liquid-Cooled ESS Containers

Applications of Second-Life Battery ESS

Second-life batteries are particularly suitable for applications that do not require high C-rate performance:

• C&I peak shaving

• Backup power for factories and telecom sites

• Community microgrids

• Solar-powered charging stations

• Behind-the-meter energy shifting

MWh-scale second-life container systems are emerging as a popular choice in Europe and Southeast Asia.

Price of Second-Life ESS

Second-life ESS pricing depends on:

• Battery degradation level

• Module reconfiguration cost

• BMS retrofitting

• Cooling system selection

• Certification requirements

Integrators typically provide project-specific quotations after evaluating battery conditions and engineering requirements.

How to Select a Second-Life ESS for Your Project?

Key considerations include:

• SoH and SoC evaluation

• Required discharge power and duration

• Cooling compatibility

• Safety design of repurposed modules

• Availability of supporting components

Large liquid-cooled units like 372kWh systems offer better thermal stability for older EV battery cells.

How Long Do Second-Life ESS Last?

Depending on the SoH of the battery, second-life ESS typically offer:

• 3000–5000 cycles

• 8–12 years usable lifetime

• Reduced degradation speed in stationary environments

The Supplier of Second-Life ESS

Suppliers require:

• Capability to reconfigure EV modules

• Mature thermal management design

• Compatibility with standard ESS platforms

• Safety testing for reused batteries

Manufacturers such as Dagong ESS support integration of reused battery modules into systems like 100kWh–241kWh ESS and 3.35MWh liquid-cooled containers, while also providing compatible accessories such as end plates, heat dissipation plates, CCS connectors, and protection films.

If you are interested in second-life battery energy storage system products, please contact Dagong ESS,Email: sales@dagongess.com